Agilent ALS Turret Manual PDF

Agilent 7693A 
Automatic Liquid
Sampler
Installation, Operation and

Maintenance
Agilent Technologies
Notices
© Agilent Technologies, Inc. 2010 Safety Notices
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2 Installation, Operation, and Maintenance

Contents
Part 1: Safety and Regulatory Information
1 Safety and Regulatory Information

Important Safety Warnings 14
Many internal parts of the instrument carry dangerous
voltages 14
Electrostatic discharge is a threat to instrument
electronics 14
Safety and Regulatory Certifications 15
Information 15
Symbols 16
Technical and environmental specifications 16
Electromagnetic compatibility 17
Sound Emission Certification for Federal Republic of
Germany 17
Fuses and battery 18
Cleaning 18
Recycling the Product 18
Part 2: Installation
2 Compatibility
Hardware 22
Firmware 22
Installation, Operation, and Maintenance 3

The G4513A Injector 23
The G4514A Sample Tray 23
The G4515A Bar Code Reader/Mixer/Heater 23
The G4520A Sample Tray with Installed Bar Code
Reader/Mixer/Heater 23
The G4522A Heating and Cooling Plate 23
The G4526A Upgrade Kit for 6890 Series GCs 24
3 Installation
Preparing the GC 26
Preparing the GC Inlet Area 27
7890A GC and 7820 MSD 27
6890 Series GCs 29
Installing the G4514A Sample Tray 33
Install the mounting bracket 34
Prepare the sample tray 35
Install the sample tray 40
Connect the communication cable 42
Installing the G4513A Injector 43
Install the injector 43
Check your work 53
Choosing the Turret Type 54
Connecting the Cables 55
7890A GC 55
7820A GC 56
6890N or 6890 Plus GC 57
6890A GC 58
6850 Series GC 59
7820 MSD 60

5975T LTM-GC/MSD 61
Test the connections 61
Parking the Sample Tray 62
Installing the Vial Racks 63
Install the vial rack labels 63
Install the vial racks 64
Remove the vial rack labels 66
Updating the Firmware 68
View the current firmware version 68
Update the firmware 69
6890A and 6890 Plus GCs 69
Configuring the GC and Data System 70
Configure the GC 70
Configure the data system 70
Calibrating the ALS System 71
Making a Trial Run 73
4 Accessories
Installing the G4526A/G4517A ALS Controller (6890A GCs) 76
Controller site requirements 76
Verify the power configuration 80
Installing the G4526A/G4516A ALS Interface Controller (6890 Plus
GCs) 81
Installing the G4515A Bar Code Reader/Mixer/Heater 85
Remove the sample tray from the GC 85
Install the G4515A Bar Code Reader/Mixer/Heater 86
Installing the G4522A Heating and Cooling Plate 96
Tools needed 96
Remove the sample tray from the GC 96
Install the heating and cooling plate 97

Reassemble the sample tray 106
Install the drainage tubing 107
Complete the installation 108
Coolant 108
Water bath and pump specifications 109
Part 3: Operation
5 Introduction to Operation
About your 7693A Automatic Liquid Sampler 114
Components 114
Features 116
Capabilities 119
Fast Injection 120
Sample Carryover 122
Solvent wash 122
Sample wash 122
Sample pump 122
Number and type of washes 122
Methods and Sequences 125
The Sampler Cycle 126
6 ALS Configuration
Configuring the Injector 130
7890A GC, 7820A GC, and 7820 MSD 130
6890 Series GC 131
6850 Series GC 133
5975T LTM-GC/MSD 134
Configuring the Sample Tray 135
7890A GC and 7820 MSD 135

6890 Series GC 137
7 ALS Parameters
Setting the Injector Parameters 142
7890A GC, 7820A GC, and 7820 MSD 143
6890 Series GC 146
6850 Series GC 148
Setting the Sample Tray Parameters 149
7890A GC and 7820 MSD 149
6890 Series GC 150
8 Syringes and Needles

Selecting a Syringe 154
Inspecting a Syringe 157
Installing a Syringe 158
Removing a Syringe 162
Replacing a Syringe Needle 163
9 Vials and Bottles

Preparing a Sample Vial 166
Select a sample vial 166
Select a vial septa 167
Label a sample vial 168
Fill a sample vial 169
Cap a sample vial 170
Preparing Solvent and Waste Bottles 172
Select the bottles 172
Fill the solvent bottles 173
Prepare the waste bottles 173

Placing Vials and Bottles in the Turret 174
Using Two Injectors (7890A and 6890 Series GCs Only) 177
With a sample tray 177
Without a sample tray 177
How Many Sample Vials Can I Run? 178
Solvent bottle equation (injector) 179
Waste bottle equation 179
Example 180
Reduced solvent and sample usage 183
Sandwich Injections 184
Example 2-layer sandwich injection 186
10 Running Samples
Running a Sample 192
Injection volume 192
Using the ALS Controller 193
Interrupting a Run or Sequence 194
Sampler response to interruptions 194
Restarting an interrupted sequence 194
Running a Priority Sample 195
Part 4: Maintenance and Troubleshooting
11 Maintenance
Periodic Maintenance 200
Tray Home and Park Positions 202

Changing the Turret 208
Adapting for Cool On-Column Injection 212
Replacing the Needle Support Foot 213
Adapting for Syringes Over 100 µL 215
Replacing the Syringe Carriage Assembly 216
Aligning the Injector 225
Aligning the Sample Tray 227
Replacing Power Fuses in the G4517A ALS Controller 231
12 Faults and Errors

Faults 234
Injector faults 234
Sample tray faults 236
Error Messages 238
13 Troubleshooting
Symptom: Variability 244
Symptom: Contamination or Ghost Peaks 246
Symptom: Smaller or Larger Peaks Than Expected 247
Symptom: Sample Carryover 249
Symptom: No Signal/No Peaks 250
Correcting Syringe Problems 251
Correcting Sample Vial Delivery Problems 252

14 Replacement Parts
G4513A Injector 254
G4514A Sample Tray 256
G4517A ALS Controller (6890A GC Only) 258
G4516A ALS Interface Board (6890 Plus GC Only) 260

Agilent 7693A Automatic Liquid Sampler
Installation, Operation and Maintenance
Part 1:
Safety and Regulatory Information
Cleaning 18
Agilent Technologies 11
1
Many internal parts of the instrument carry dangerous voltages 14
Electrostatic discharge is a threat to instrument electronics 14
Information 15
Symbols 16
Technical and environmental specifications 16
Electromagnetic compatibility 17
Sound Emission Certification for Federal Republic of Germany 17
Fuses and battery 18
Cleaning 18
This chapter provides important safety and regulatory information about

the Agilent 7693A Automatic Liquid Sampler (ALS) system.
Important Safety Warnings

There are several important safety notices that you should always keep in
mind when using the ALS (including any injector, tray, or powered
accessory).
Many internal parts of the instrument carry dangerous voltages

With the GC power switch on, potentially dangerous voltages can exist on:
• All electronics boards in the instrument
• The internal wires and cables connected to these boards
If using a G4517A ALS Controller and it is connected to a power source,
even if the power switch is off, potentially dangerous voltages exist on:
• The wiring between the instrument power cord and the AC power
supply
• The AC power supply itself
• The wiring from the AC power supply to the power switch
• The wiring from the G4517A ALS Controller to any injector or sample
tray
All these parts are shielded by covers. With the covers in place, it should be difficult
WA R N I N G
to accidentally make contact with dangerous voltages. Unless specifically
instructed to, never remove a cover.
If the power cord or wiring from the instrument to the gas chromatograph insulation
WA R N I N G
is frayed or worn, the cord must be replaced. Contact your Agilent service
representative.
Electrostatic discharge is a threat to instrument electronics

The printed circuit (PC) boards in the instrument can be damaged by
electrostatic discharge. Do not touch any of the boards unless it is
absolutely necessary. If you must handle them, wear a grounded wrist
strap and take other antistatic precautions. Wear a grounded wrist strap
any time you must remove the electronics cover.

Safety and Regulatory Certifications

The ALS conforms to the following safety standards:
• International Electrotechnical Commission (IEC): 61010–1
• EuroNorm (EN): 61010–1
In addition to the above Safety and Regulatory Certifications, the G4517A
ALS Controller conforms to the following safety and regulatory
certifications:
• Canadian Standards Association (CSA): C22.2 No. 1010.1
• CSA/Nationally Recognized Test Laboratory (NRTL): UL 61010A–1
The instrument conforms to the following regulations on Electromagnetic
Compatibility (EMC) and Radio Frequency Interference (RFI):
• CISPR 11/EN 55011: Group 1, Class A
• IEC/EN 61326- 1
• AUS/NZ N10149
This ISM device complies with Canadian ICES- 001. Cet appareil ISM est
conforme a la norme NMB—001 du Canada.
The instrument is designed and manufactured under a quality system

registered to ISO 9001.
Information
The Agilent Technologies ALS meets the following IEC (International
Electrotechnical Commission) classifications: Safety Class I, Transient
Overvoltage Category II, Pollution Degree 2.
This unit has been designed and tested in accordance with recognized
safety standards and is designed for use indoors. If the instrument is used
in a manner not specified by the manufacturer, the protection provided by
the instrument may be impaired. Whenever the safety protection of the
Agilent ALS has been compromised, disconnect the unit from all power
sources and secure the unit against unintended operation.

Refer servicing to qualified service personnel. Substituting parts or

performing any unauthorized modification to the instrument may result in
a safety hazard.
Symbols
Warnings in the manual or on the instrument must be observed during all
phases of operation, service, and repair of this instrument. Failure to
comply with these precautions violates safety standards of design and the
intended use of the instrument. Agilent Technologies assumes no liability
for the customer’s failure to comply with these requirements.
See accompanying instructions for more

information.
Indicates a hot surface.
Indicates hazardous voltages.
Indicates earth (ground) terminal.
Indicates explosion hazard.
Indicates electrostatic discharge hazard.
Technical and environmental specifications

• Indoor use only in ordinary atmospheres
• Altitude up to 4300 m
• Operating ambient temperatures between 5 degrees centigrade and
55 degrees centigrade
• Maximum relative humidity of 80 % for temperatures up to 31 degrees
centigrade decreasing linearly to 50 % relative humidity at 40 degrees
centigrade

• Pollution degree 2, Installation Cat II

In addition to the above technical and environmental specifications, the
G4517A ALS Controller conforms to the following technical and
environmental specifications:
• Rated for mains connection to 100–120 VAC or 220–240 VAC, 50/60 Hz, 
180 VA
• Main supply voltage fluctuations up to ±10% of the nominal voltage
Electromagnetic compatibility
This device complies with the requirements of CISPR 11 and IEC 61326- 1.
Operation is subject to the following two conditions:
1 This device may not cause harmful radio frequency interference.
2 This device must accept any radio frequency interference received,
including interference that may cause undesired operation.
If this equipment does cause harmful interference to radio or television
reception, which can be determined by turning the equipment off and on,
the user is encouraged to try one or more of the following measures:
1 Relocate the radio or antenna.
2 Move the device away from the radio or television.
3 Plug the device into a different electrical outlet, so that the device and
the radio or television are on separate electrical circuits.
4 Make sure that all peripheral devices are also certified.
5 Make sure that appropriate cables are used to connect the device to
peripheral equipment.
6 Consult your equipment dealer, Agilent Technologies, or an experienced
technician for assistance.
7 Changes or modifications not expressly approved by Agilent
Technologies could void the user’s authority to operate the equipment.
Sound Emission Certification for Federal Republic of Germany
Sound pressure
Sound pressure Lp < 82 dB(A) according to DIN- EN 27779
(Type test).

Schalldruckpegel
Schalldruckpegel LP < 82 dB(A) nach DIN- EN 27779 (Typprufung).
Fuses and battery

Table 1 lists replaceable fuses in the G4517A ALS Controller module. Any
fuses in the G4516A ALS Interface Controller Board should only be
accessed by Agilent service personnel.
There are no fuses in any other 7693A ALS components.
Table 1 G4517A ALS Controller fuses
Fuse designation Location Fuse rating and type
2A G4517A Power line module 2A 250V, type T (220–240 V power supply)
2A G4517A Power line module 2A 250V, type T (100–120 V power supply)
The G4517A ALS Controller also contains a non- replaceable 3 V lithium

ion battery.
Cleaning
To clean the external surfaces of the injector tower and sample tray,
disconnect the power and wipe down with a damp, lint- free cloth. Refer to
“Periodic Maintenance” on page 200 for more information.
Recycling the Product

For recycling, contact your local Agilent sales office.

Part 2:
Installation
Compatibility 21
Hardware 22
Firmware 22
Installation 25
Preparing the GC 26
Accessories 75
GCs) 81
2
Compatibility
Hardware 22
Firmware 22
This chapter assists you in determining whether the 7693A ALS system is
suitable for your Agilent Gas Chromatograph (GC) and aids in identifying
existing equipment.
2 Compatibility
Hardware
The 7693A ALS system is compatible with the following Agilent
instruments:
• 7890A GC
• 7820A GC
• 6890 Series GC
• 6850 Series GC
• 7820 MSD
• 5975T LTM- GC/MSD
Firmware
Agilent GCs require the minimum firmware revisions listed in Table 2.
To update the firmware, use either the provided Instrument Utility on the
GC and GC/MS Hardware User Information & Utilities DVD, or the Agilent
Lab Advisor software.
Table 2 Minimum GC firmware revisions for 7693A ALS system use
Instrument Minimum firmware version required
7890A GC A.01.10
7820A GC A.01.01
6890N GC N.06.07
6890A GC A.03.08 (chip set)
6890 Plus GC A.03.08 (chip set)
6850 GC with serial number < US00003200 A.03.07
6850 GC with serial number > US10243001 A.06.02

(includes 6850 Network and Series II)
7820 MSD A.01.01 (GC)
5975T LTM-GC/MSD A.03.02.005 (GC) / 5.02.07 (MSD)
22 Installation, Operation, and Maintenance

Part 2, Installation
Compatibility 2
The G4513A Injector

The G4513A Injector is designed for the Agilent 7693A ALS system. No
other injector models are compatible.
The G4514A Sample Tray

The G4514A Sample Tray is designed for the Agilent 7693A ALS system.
No other sample tray models are compatible.
Samples may be handled entirely with the 16- sample standalone turret or
the 3- sample transfer turret supplied with the injector. The G4514A
Sample Tray has a capacity of 150 samples.
The G4515A Bar Code Reader/Mixer/Heater

The G4515A Bar Code Reader/Mixer/Heater (BCR) is designed for the
Agilent 7693A ALS system, and provides positive sample identification
checks, plus single vial heating and mixing capabilities. No other BCRs,
mixers, or heaters are compatible.
The G4520A Sample Tray with Installed Bar Code Reader/Mixer/Heater

The G4520A Sample Tray with pre- installed BCR/Mixer/Heater is identical
to the individual parts G4514A Sample Tray and G4515A
BCR/Mixer/Heater. In this manual it is assumed that any reference to
G4514A or G4515A also applies to the G4520A accessory.
The G4522A Heating and Cooling Plate

The Agilent G4522A Heating and Cooling Plate is designed specifically for
the G4514A Sample Tray. No other cooling accessories are compatible.
Installation, Operation, and Maintenance 23

2 Compatibility
The G4526A Upgrade Kit for 6890 Series GCs

The G4526A Upgrade Kit is required for any 6890 Series GC with an
Agilent 7693A ALS system. The Upgrade Kit includes the following:
• G1530- 40205 Inlet Fan Cover
• G1530- 40070 Injection Port Top Cover (tahitian teal)
• 0515- 2496 M4 × 0.7 12 mm screw (3)
• 1390- 1024 M4 × 0.7 screw (1)
• G4600- 64006 GC/GCMS Hardware User Information & Utilities DVD
The following options are available depending on your 6890 GC type:
• Option 001-Required for 6890A GCs with the last five serial numbers
< 20000. Includes the external G4516- 64000 ALS Controller.
• Option 002-Required for 6890 Plus GCs with the last five serial
numbers > 20000. Includes the G4517- 64000 ALS Interface Board
controller.
• Option 003-Required for all 6890N GCs. Includes the G1530- 41205
Inlet Fan Cover and the G1530- 40075 Injection Port Top Cover (tahitian
teal) for older 6890N GC models, or the G1530- 41075 Injection Port Top
Cover (light gray) for newer 6890N GC models.
If your 6890A or 6890 Plus GC does not have a LAN connection, the G2335A 6890 LAN kit is
NOTE also required.

3
Installation
Preparing the GC 26
The procedure for installing the 7693A ALS depends on the system
components purchased and the type of GC involved. In all cases, you must
remove any existing ALS system components before installation. Older GCs
will require firmware updates. Follow the steps in this chapter that are
relevant to your GC and ALS system setup.
3 Installation
Preparing the GC
This procedure explains how to prepare an Agilent GC for the 7693A ALS
system.
The inlet may be hot enough to cause skin burns. Allow the inlet to cool to ambient
WA R N I N G
temperature before working near the inlet.
1 Set the GC inlets, detectors, and oven to room temperature.

2 After the GC inlets, detectors, and oven have cooled, turn off the GC
and unplug the power cord.
3 If installed, unplug any ALS component cables. Remove any injectors,
injector inlet mounting posts, parking posts, tray brackets and supports,
and sample tray from the GC.
For details, refer to the sampler’s original documentation.

Installation 3
Preparing the GC Inlet Area

This procedure explains how to prepare the 7890A GC, the 6890 Series
GC, and the 7820 MSD inlet area for the 7693A ALS system.
If you have a 7820A GC, a 6850 Series GC, or the 5975T LTM- GC/MSD,
skip this section.
The inlet may be hot enough to cause skin burns. Allow the inlet to cool to ambient
WA R N I N G
temperature before working near the inlet.
7890A GC and 7820 MSD

The 7890A GC and 7820 MSD inlet area (injection port top cover, inlet fan
cover) is designed to be fully- compatible with the 7693A ALS system, but
must be prepared if installing a sample tray. If not installing a sample
tray, skip this section.
This section contains instructions and photos for the 7890A GC. Steps for
the 7820 MSD are similar.

3 Installation
Remove five of the seven screws securing the inlet cover to the GC. Do not
remove the two screws in the locations shown below.
Do not remove the screws in these locations

Installation 3
6890 Series GCs

All 6890 Series GCs require the replacement of the inlet fan cover before
installing any component of the 7693A ALS system. Most 6890 Series GCs
also require the replacement of the injection port top cover. The procedure
below prepares the 6890 Series GC inlet area for the 7693A ALS system.
Replace the inlet fan cover

The inlet fan cover encloses the fan that draws air through the 6890 GC
inlets.
1 Loosen the Torx T- 20 screw on the right side of the fan cover. See
Figure 2 on page 31 for screw location.
2 Slide the cover slightly to the right to disengage it from the left
mounting post and lift the cover up and off.
3 Lower the replacement inlet fan cover (G1530- 41205) and engage it to
the left mounting post.
4 Install the Torx T- 20 screw on the right side of the fan cover until
tight.

3 Installation
Replace the injection port top cover

The injection port top cover is the plastic cover mounted over the two
inlets. In most cases, you will need to replace the injection port top cover
before using the 7693A ALS system. However, some later- model 6890
Series GCs were manufactured with a compatible injection port top cover.
If your injection port top cover has the two features noted in Figure 1,
then you can skip this section. Otherwise follow the procedure below.
Figure 1 Compatible injection port top cover features

Installation 3
1 Fully loosen the six Torx T- 20 screws on the top of the cover
(Figure 2).
Inlet cover screws
Fan cover screw
Figure 2 Removing the injection port top cover and inlet fan cover (6890 Series GC)
2 Lift off the cover.

3 Set the replacement inlet cover (G1530- 41075) on the GC. Make sure all
plumbing and wires are properly routed in their channels.

3 Installation
4 Secure the replacement injection port top cover using two screws from
the original inlet cover in the hole locations (Figure 3).
Reuse screws from

original cover
Figure 3 Replacing the injection port top cover and inlet fan cover (6890 Series GC)
5 If installing a sample tray, cover replacement is complete. Be sure to

store the remaining screws in a safe location. Skip to the next section.
If not installing a sample tray, install the remaining four Torx T- 20
screws on the injection port top cover.

Installation 3
Installing the G4514A Sample Tray

This procedure explains how to install the G4514A Sample Tray on the
7890A GC, the 6890 Series GC, and the 7820 MSD.
If you have a 7820A GC, a 6850 Series GC, a 5975T LTM- GC/MSD, or are
not planning to install a sample tray, skip this section.
If you have a 6890A GC, be sure to install the G4526A/G4517A ALS
Controller before installing the G4514A Sample Tray. See “Installing the
G4526A/G4517A ALS Controller” for more information.
If you have a 6890 Plus GC, be sure to install the G4526A/G4516A ALS
Interface Controller before installing the G4514A Sample Tray. See
“Installing the G4526A/G4516A ALS Interface Controller” for more
information.

3 Installation
Install the mounting bracket

1 Attach the mounting bracket (G4514- 63000) to the inlet cover.
1390-1024
Screw M4
0515-0437
Screw M4
G4514-20529
Washer

Installation 3
Prepare the sample tray
Take care when holding the tray. Because the motors are heavy and located
WA R N I N G
off-center, an improper balance point can cause the tray to tip out of your grasp.
1 Set the tray on a secure, flat surface. Position the tray on its side so
the tray bracket faces up. Let the gantry slide all the way down.
Gripper jaw
Slide out
Expose packing screw
Gantry
Slide down
2 Slide the gripper jaw away from the tray base until the packing screw
is accessible.

3 Installation
3 Remove the packing screw using a Phillips screw driver and tweezers.
Packing screw

Installation 3
4
T-20

3 Installation
7
T-20

Installation 3

3 Installation
Install the sample tray

1 Using both hands, carefully hang the sample tray bracket over the
mounting bracket tabs (Figure 4). Try to keep the gantry from sliding
towards the tray bracket while performing this step.
2 Tilt the tray, line up the tray bracket with the tabs on the mounting
bracket, and slowly lower into place.
Figure 4 Hanging the tray bracket over the mounting bracket tabs.

Installation 3
3 Once attached, make sure that the sample tray is lying flat against the
mounting bracket. Each tab on the mounting bracket must be fully
latched to the tray bracket (Figure 5).
Figure 5 Sample tray correctly installed.
Figure 6 Sample tray incorrectly installed.

3 Installation
4 Secure the sample tray to the mounting bracket by installing three T- 30

Torx screws.
Connect the communication cable

1 Connect the communication cable to the sample tray. See “Connecting
the Cables” on page 55 for more information.

Installation 3
Installing the G4513A Injector
Install the injector

This procedure explains how to install the G4513A Injector.
If installing the G4514A Sample Tray with your ALS system, you must
install the mounting bracket first. See “Install the mounting bracket” on
page 34 for more information.
If you have a 6890A GC, be sure to install the G4526A/G4517A ALS
Controller before installing the G4514A Sample Tray. See “Installing the
G4526A/G4517A ALS Controller” for more information.
If you have a 6890 Plus GC, be sure to install the G4526A/G4516A ALS
Interface Controller before installing the G4514A Sample Tray. See
“Installing the G4526A/G4516A ALS Interface Controller” for more
information.

3 Installation
1 Install the parking post(s) on the GC. If you have a 5975T

LTM- GC/MSD, skip to the next step.
Parking post
positions
Figure 7 Parking post positions (7890A shown)
2 Lay the injector on a flat surface, or mount the injector on a parking

post.
3 Remove the shipping tape from the turret and injector tower door.
4 Open the injector door.

Installation 3
5 Using a T- 10 Torx driver, completely loosen the T- 10 screw and remove

the shipping clamp from the syringe carriage (Figure 8 and Figure 9).
Shipping clamp
Figure 8 Shipping clamp installed.

3 Installation
Figure 9 Shipping clamp removed.
6 Close the injector door.

Installation 3
In the following steps, use a flat blade screwdriver that snugly fits the slot in the top of
CAUTION
the posts. An undersized blade can damage the post top and prevent the injector from
mounting properly.
Do not mount the G4513A Injector on a mounting post for any other injector; this can
CAUTION damage the injector. Remove the old post and replace it with the new one.
7 Install the injector mounting post (G4513- 20561, Figure 10) to the GC
inlet cover’s threaded connection. If the wrong post is used (for
example the 7683B ALS mounting post) the injector will not work. The
mounting post supplied in this kit only supports the G4513A Injector.
Figure 10 Mounting post (G4513-20561)

3 Installation
• 7890A GC, 7820A GC, and 7820 MSD. Install into the inlet cover in
the front or rear location, as desired. The post must be turned all the
way down (Figure 11).
Mounting posts
Front injector position Back injector position
Figure 11 Installing the mounting post(s) on a 7890A GC

Installation 3
• 6890 Series GC. Install into the inlet cover in the front or rear
location, as desired. The post must be turned all the way down
(Figure 12).
Back
Front
6890
Figure 12 Installing the mounting post(s) (6890 GCs)
• 6850 Series GC. Install into the inlet mounting bracket. Loosen the
inlet screws, install the post and tighten the screws. The post must
be turned all the way down (Figure 13).
6850
Figure 13 Installing the mounting post (6850 GCs)

3 Installation
• 5975T LTM- GC/MSD. Install into the inlet mounting bracket. The
post must be turned all the way down (Figure 14).
5975T LTM-GC/MSD
Figure 14 Installing the mounting post (5975T LTM-GC/MSD)

Installation 3
8 If a sample tray is installed, route the front injector cable through the
mounting bracket support structure. If installing a back injector, make
sure the cable is available.
Front injector cable Front injector cable routed Back injector cable
through mounting bracket support
Figure 15 Front injector cable routed through mounting bracket support.
9 If installing a back injector, connect the back injector cable to the

injector cable port.
Injector cable port

3 Installation
10 Position the back injector on the mounting post and the back inlet
cover’s support foot.
Back injector
11 If installing a front injector, connect the front injector cable to the

injector cable port.
Injector cable port

Installation 3
12 Position the front injector on the mounting post and the front inlet
cover’s support foot.
Front injector
Check your work

The injector must be vertical and stable.
If the injector will not sit upright on the GC, check that the plumbing and
cabling under the inlet cover are properly routed in their channels. Also
verify that the front injector cable is routed correctly through the GC
mounting bracket support as shown in Figure 15 on page 51.

3 Installation
Choosing the Turret Type

Two interchangeable sample turrets are provided with the injector:
• The standalone turret allows you to analyze up to 16 samples. It holds
two solvent positions and one waste bottle position. Two sample
positions can be alternately configured for sample preparation. The
standalone turret is not compatible with the sample tray.
• The transfer turret is designed to work with the sample tray to analyze
up to 150 samples. The transfer turret has three sample vial transfer
locations; two of which are configurable for use in sample preparation.
There are six solvent A positions, four solvent B positions, and five
waste positions. This turret can be used with or without the sample
tray.
The injector comes with the transfer turret installed. If you wish to use
the 16- sample standalone turret, see “Changing the Turret” for details.
No other turrets are compatible with the G4513A Injector.

Installation 3
Connecting the Cables

This section shows the cable routing for a 7693A ALS system with a GC.
7890A GC
Follow the instructions below to properly wire the injector and sample
tray to the 7890A GC.
7890A GC
Sampler1 Sampler2 Tray
Cables (G4514-60610)
Inj1 Inj2
Tray (Includes optional BCR)
Front Back
Injectors
Power cords not shown

Figure 16 Cables for 7890A GC
1 Connect the injector(s) to the GC with a G4514- 60610 cable(s).

2 Connect the tray to the GC with a G4514- 60610 cable.
3 Connect the GC power cord to the outlet.

3 Installation
7820A GC
Follow the instructions below to properly wire the injector to the 7820A
GC.
7820A GC
ALS Port
Front Back
Cables (G4514-60610)
Front Back
Injector Injector
1 Connect the injector to the GC with a G4514- 60610 cable.


Installation 3
6890N or 6890 Plus GC

tray to a 6890N or 6890 Plus GC.
6890 Plus or 6890N GC
Sampler1 Sampler2 Tray
Cables (G4514-60610)
Inj1 Inj2
Front Back
Injectors

Figure 18 Cables for 6890 Plus and 6890N GCs
1 Connect the injector(s) to the GC with a G4514- 60610 cable(s).


3 Installation
6890A GC
Follow the instructions below to properly wire the 6890A GC to the
G4517A ALS Controller, and the controller to the injector(s) and sample
tray. See “Installing the G4526A/G4517A ALS Controller” for installation
instructions for the G4517A ALS Controller including the power supply
cord.
G4517A Controller
G1530-60930 6890 Remote
Front Back
RS-232 Injector Injector Tray
Cables (G4514-60610)
Remote
Inj1 Inj2
6890A GC Tray
Front Back
Sampler G1530-60600
Injectors (Includes optional BCR)
1 Connect the injector(s) to the ALS controller with a G4514- 60610

cable(s).
2 Connect the sample tray to the ALS controller with a G4514- 60610
cable.
3 Connect the ALS controller to the GC with a G1530- 60930 cable and a
G1530- 60600 cable.
4 Connect the GC and controller power cords to the outlets.

Installation 3
6850 Series GC
Follow the instructions below to properly wire the 6850 Series GC to the
to the injector.
G4513A Injector
6850 Series GC
Injector cable
(G4514-60610)
Connect to top connector
Power cord not shown

Figure 20 Cable for 6850 Series GC
1 Connect the injector(s) to the controller with a G4514- 60610 cable. Use
the top injector connection on the back of the GC. See Figure 20.

3 Installation
7820 MSD
tray to the 7820 MSD.
7820 MSD
7820A GC
Sampler1 Tray
Cables (G4514-60610)
Inj1
Front
Injector

Figure 21 Cables for 7820 MSD


Installation 3
5975T LTM-GC/MSD
tray to the 5975T LTM- GC/MSD.
5975T LTM-GC/MSD
Sampler1
Cable (G4514-60610)
Inj1
Front
Injector

Figure 22 Cables for 5975T LTM-GC/MSD

Test the connections

When the cables are connected, turn on the GC power. After the start- up
process ends:
• The Ready light on the injector tower should be on.
• If the Align Mode light on the injector tower is on, see “Aligning the
Injector”.
• If the Fault light on the sample tray is on, see “Faults”.

3 Installation
Parking the Sample Tray

If a sample tray is installed, follow the procedure below to park the
sample tray. If you do not have a sample tray, skip this section.
1 Power on the GC.
2 Park the sample tray by pushing the [P] button on the sample tray front
panel.
The gantry will move to the far- left position (away from the tray bracket),
and gripper jaw will move to the far- back position (away from the tray
front panel). This allows for clear access to the tray base.
To operate the sample tray, the gantry must be out of the Park position. Press [P] on the
NOTE tray front panel to move the gantry from the Park position to the Home position.

Installation 3
Installing the Vial Racks

If a sample tray is installed, follow the procedure below to install the vial
racks. If you do not have a sample tray, skip this section.
Install the vial rack labels

Before using the vial racks, you must install the vial rack labels:
1 Place the vial racks on a flat surface.
2 Align the vial rack label with the front of the vial rack so that the lip
of the vial rack label fits over the front of the vial rack. The tabs on
the underside of the vial rack label will align with the insert holes on
the vial rack.
3 Press the vial rack label down into the vial rack until it snaps into
place.
Vial rack label
Vial rack label lip

3 Installation
Install the vial racks

1 After the vial rack labels are installed, lower the back end of the vial
rack into the tray base.

Installation 3
2 Align the tab found on the back side of the vial rack with the hole in
the tray’s back wall.
3 Lower the front of the vial rack so that it fits into place and rests flat
on the tray base. The LED light below each vial rack will light if the

3 Installation
vial rack is present. Be sure to install the vial racks so the vial rack
label numbers are in sequential order from right to left.
4 Repeat the process for the two remaining vial racks.
Remove the vial rack labels

Skip this section if you do not wish to remove the vial rack labels. To
remove the vial rack labels:
1 Hold the vial rack upside- down.

Installation 3
2 Using your free hand, pinch the two tabs towards each other until the
vial rack label snaps out of the vial rack.
Vial rack label tabs

3 Installation
Updating the Firmware

The 7693A ALS requires the firmware revisions noted in Table 2. Before
using the 7693A ALS system, check the firmware revisions as described
below.
Whether you are using Agilent Instrument Utilities or Lab Advisor
software to update your firmware, you can download the latest firmware
revisions from the Agilent web site at www.agilent.com/chem, or contact
your local Agilent sales representative.
Failure to update the firmware will result in unrecognized components,
vial delivery errors, or fewer available features.
View the current firmware version

To view the current firmware version for the GC or installed ALS
components:
All GCs Power cycle the instrument. When it reboots, it displays the
current firmware version.
7890A GC Press [Status] > [Clear], or press [Service Mode] > Diagnostics >
Instrument status to display the current GC firmware version. To view the
current ALS component firmware, press [Service Mode] > Diagnostics > ALS
Status. Scroll through the menu to view the ALS controller, Front/Back
Tower, Tray, and BCR firmware versions.
7820A GC, 7820 MSD Using the software keypad, press [Status] > [Clear], or
press [Service Mode] > Diagnostics > Instrument status to display the current GC
firmware version. To view the current ALS component firmware, press
[Service Mode] > Diagnostics > ALS Status. Scroll through the menu to view the
ALS controller, Front/Back Tower, Tray, and BCR firmware versions.
All 6890 GCs Press [Options], then select Diagnostics > Instrument Status.
Scroll down to view the GC and ALS component firmware versions. For
6890A GCs the G4517A ALS Interface Controller, Front/Back Tower,
Sample Tray, and BCR firmware versions are displayed. For 6890N GCs
the sample tray and BCR firmware versions are displayed.

Installation 3
5975T LTM-GC/MSD Press [Menu] to scroll to + Version or + LTM GC, and

use the [Item] key to scroll to the desired component firmware
information. Use an Agilent data system to view the injector firmware
information.
Update the firmware

To update the firmware, use either the provided Instrument Utility on the
GC and GC/MS Hardware User Information & Utilities DVD, or the Agilent
Lab Advisor software. Refer to the software help and user documentation
for firmware update information.
Once you connect to an instrument in the software’s Firmware Update
screen, no other tasks can be performed on the instrument until you
disconnect.
6890A and 6890 Plus GCs

The Agilent Instrument Utilities or Lab Advisor software can display the
firmware version for these GCs but cannot update them. These GCs use
programmable chips that must be physically replaced. Contact your local
Agilent service representative.

3 Installation
Configuring the GC and Data System
Configure the GC
When hardware installation is complete, configure your GC for use with
the 7693A ALS system. See “ALS Configuration” for details. Be sure to
check:
• Injector usage
• Solvent bottle usage
• Solvent volume usage
Configure the data system
Configuration
Agilent ChemStation, Agilent MSD ChemStation, and Agilent EZChrome
Elite data systems contain information about the sampling equipment in
use. This must be updated to remove the old information and replace it
with information about the new equipment that you have installed. See
your data system documentation for details.
Upgrading methods
Before using methods created for a previous sampler system, be sure to
edit them as needed to match the new hardware.

Installation 3
Calibrating the ALS System

If a sample tray is installed, follow the procedure below to calibrate the
ALS system. If you do not have a sample tray, skip this section.
The ALS system calibration process aligns the sample tray with the
injector turret position so vial transfers occur without incident.
Calibration should be performed if a calibration does not exist, and also
as a routine maintenance procedure.
Calibrating the ALS system is recommended if any ALS components are
moved.
To calibrate your ALS system:
1 Place the calibration vial (G4514- 40588) in tray position 1 (Figure 23).
Figure 23 Tray position 1

3 Installation
2 Remove any vials from transfer turret positions L1, L2, and L3 for all
installed injectors (Figure 24).
L1
L2
L3
Figure 24 Transfer turret positions L1, L2, L3 (top view)
3 Start the ALS system calibration:

• On a 7890A GC, use the GC front keypad and select [Options]
Calibration > ALS > Start Calibration.
• On a 6890 Series GC, use the GC front keypad and select [Options]
Calibration > Sample tray > Start Calibration.
The following calibration process will occur for all installed injectors:
a The tray assesses the turret alignment by placing the calibration vial
into turret position L1 and returning to sample tray position 1.
b The tray tests the vial height and turret position by using the
alignment tab between positions L1 and L2 on the transfer turret.
c The tray verifies the turret alignment by placing the calibration vial
into turret position L1 and returning it to sample tray position 1.
4 When the calibration process is complete, the green Ready status light
will come on and the gantry will stop in the Home position (Figure 61
on page 202).
Remember to replace any vials that were moved for the calibration
process.

Installation 3
Making a Trial Run

Once installation, configuration, updating, and calibration is complete,
make a quick injection using the sampler to verify that it works properly.
1 Install an empty syringe in the injector.
2 If using the G4514A Sample Tray with the G4513A Injector, make
sure the transfer turret is installed. See “Changing the Turret” for
details.
If using only the G4513A Injector, replace the transfer turret with the
standalone turret, if desired. See “Changing the Turret” for details.
3 Place empty bottles in all the Solvent A and Waste A turret positions.
Place an empty capped sample vial in the tray 1 position (or the turret
sample 1 position, if not using the sample tray).
4 Make the sampler settings shown in Table 3. These are designed for a
7890A GC. If you are using a different GC, use these settings as a
guide.
For 7890A and 6890 GCs Use the front keypad
For 6850 GCs Use your Agilent data system
Table 3 Trial run parameters

Parameter Setting
Injection volume 1.00
Viscosity delay 0
Inject Dispense Speed 6000
Airgap Volume 0.20
Sample Pumps 6
Sample Washes 0
Solvent A post washes 1
Solvent A pre washes 1
Solvent B post washes 0
Solvent B pre washes 0
Sample Draw Speed 300
Pre dwell time 0
Post dwell 0

3 Installation
Table 3 Trial run parameters (continued)

Parameter Setting
Sample offset 0
Injection Mode Normal (1-layer injection)
Tower LED On
5 Set the GC oven program to 30 °C (or current room temperature) with

a 0 °C/min ramp, a hold time of 0.1 minutes, an equilibrium time of
0.3 minutes, and an initial time of 0.3 minutes.
6 Store, load, then run the sequence.
If there are no faults, the injector will make one injection from the first
vial position.
If problems occur, see “Faults”, “Error Messages”, “Correcting Syringe
Problems”, or “Correcting Sample Vial Delivery Problems”.

4
Accessories
GCs) 81
The procedure for installing the 7693A ALS accessories depend on the
system components purchased and the type of GC involved. Follow the
steps in this chapter that are relevant to your GC and ALS system setup.
4 Accessories
Installing the G4526A/G4517A ALS Controller (6890A GCs)

This procedure applies to the 6890A GC only. If you do not have a 6890A
GC, skip this section.
Controller site requirements

This procedure explains how to install the G4517A ALS Controller on a
6890A GC.
Temperature and humidity ranges

The ALS system is designed for indoor use only in ordinary atmospheres.
Temperature range 5 °C to 55 °C
Relative humidity range Maximum relative humidity of 80% for
temperatures up to 31 °C decreasing linearly to
50% relative humidity at 40 °C
Altitude range Up to 4300 m
After exposing the ALS controller to extremes of temperature or humidity,

allow 15 minutes for it to return to the recommended ranges.
Ventilation requirements
The controller is cooled by air flow which enters the front of the
instrument and exits through the rear. Do not4obstruct air flow in the
front or rear of the instrument.

Accessories 4
Benchtop space requirements

Figure 25 shows the space requirements around the controller. The area in
the back of the controller must be kept clear for easy operation of the
power switch and the front of the controller requires access to the front
panel buttons.
15 cm minimum
G4517AA
31 cm Controller
Front
25 cm
Figure 25 Benchtop space requirements
Dimensions
25 cm (9.84 in) wide × 31 cm (12.2 in) deep × 11 cm (4.33 in) high × 5 kg
(11 lbs) weight

4 Accessories
Orientation
The G4517A ALS Controller is designed to be installed in a horizontal
orientation as shown in Figure 26. If mounted in the vertical orientation,
the probability of tipping increases with the possibility of injury to
personnel.
ALS Controller
ALS Controller
ALS Controller
Horizontal recommended Vertical
Figure 26 ALS controller orientation
Electrical requirements
A proper earth ground is required.

CAUTION
Grounding To protect users, the cabinet is grounded through the

three- conductor power line cord in accordance with International
Electrotechnical Commission (IEC) requirements.
The three- conductor power line cord, when plugged into a properly
grounded receptacle, grounds the instrument and minimizes shock hazard.
A properly grounded receptacle is one that is connected to a suitable
earth ground. Proper receptacle grounding should be verified.

Accessories 4
Any interruption of the grounding conductor or disconnection of the power cord

WA R N I N G
could cause a shock that could result in personal injury.
Line voltage The G4517A ALS Controller operates from one of the AC
voltage supplies listed in Table 4, depending on the standard voltage of
the country from which it was ordered. It is designed to work at a
specific voltage; make sure your instrument’s voltage option is
appropriated for your lab. The voltage requirement is printed near the
power cord attachment. See “Verify the power configuration” on page 80
for setting the proper voltage for this controller.
Table 4 Voltage requirement by country
Country Voltage Part number

Americas, 10 amp 120 V 8120-1378
Argentina 220 V 8120-6869
Australia, 10 amp 240 V 8120-1369
Chile, 10 amp 220 V 8120-6978
China, 10 amp 220 V 8121-0723
DK/Greenland, 10 amp 220 V 8120-3997
Europe, 10 amp 230 V 8120-1689
GB/HK/SG/MY, 10 amp 240 V 8120-8705
India/S Africa, 10 amp 240 V 8120-4211
Israel, 10 amp 220 V 8120-5182
Japan, 10 amp 200 V 8120-4753
Korea, 10 amp 220 V 8121-1226
Switzerland, 10 amp 230 V 8120-2104

4 Accessories
Verify the power configuration

The G4517A ALS Controller can be configured for either 110–120 V power
or for 220–240 V power.
Failure to configure the correct voltage setting will blow the fuses.
CAUTION
To determine the current power configuration, look at the back panel of

the controller. The fuse holder module below the power cord receptacle is
labeled with 220–240 V on one edge and with 110–120 V on the other
(Figure 27).
Notch 110-120 V
220-240 V
DES FUSIBLES DE 250V
USE ONLY WITH 250V UNIQUEMENT AVEC
FUSES/EMPLOYER FUSES/EMPLOYER
UNIQUEMENT AVEC USE ONLY WITH 250V
110-120 V 220-240 V
Indicates current voltage configuration
Configured for 110-120 V Configured for 220–240 V
Figure 27 G4517A power configurations
To change the power configuration, remove the fuse holder module using a
small, flat- bladed screwdriver in the notch at the top of the fuse holder.
Turn it over and reinstall. See Figure 27.

Accessories 4
Installing the G4526A/G4516A ALS Interface Controller (6890 Plus GCs)

This procedure explains how to install the G4516A ALS Interface
controller board on the 6890 Plus GC. If you do not have a 6890 Plus GC,
skip this section.
The G4516A ALS Interface controller board must be present in a 6890
Plus GC to operate the 7693A ALS. The GC must have a serial number
greater than 20,000.
Before proceeding, turn off the main power switch and unplug the power cord.
WA R N I N G
Make sure you are properly grounded with an ESD strap before continuing.
CAUTION
1 Remove the GC back panels and the right side cover.
Attempting to slide the entire board under the locking tab will damage the board’s
CAUTION
components.

4 Accessories
2 Hold the board upright and slightly angled (Figure 28).
Step 4.
Align tabs Step 5.
and cutouts Insert board
Step 6. to stops
Secure board
with screws Step 3.
Place board
in bracket
Step 7.
Connect
transformer
cable
Step 2.
Hold board
at an angle
Figure 28 Installing the ALS interface board
3 Place the board onto the mounting bracket.

4 Slide it into the bracket until the cutouts in the board are aligned with
the locking tabs in the bracket.
5 Lay the board against the chassis then slide it in until it stops. The
locking tabs should hold the board in place.
6 Secure the board to the chassis using two screws. The board should not
be stressed or bowed against the locking tab (Figure 28).
7 Locate the 2- wire cable leading from the transformer and connect it to
the ALS Interface board at J5. (Figure 28 and Figure 29).

Accessories 4
P5, controller cable (step 9) connects here

J5, cable from transformer (step 7) connects here
Figure 29 ALS interface connectors
8 If an MIO card (LAN card) is installed, loosen its two mounting screws
and slide the card out of the GC (Figure 30).
Figure 30 Removing the LAN card

4 Accessories
9 Connect the Controller PCB Cable, part no. G2612- 60510, to the main
board at J8 and to the ALS Interface board at P5. Route the cable
through the cutout in the main board (Figure 29 and Figure 31).
J8, controller cable

connects here
Figure 31 GC main board
10 If an MIO card was removed from the GC, reinstall it.
11 Using a nut driver, remove the cover plate over the three holes labeled
Injector 1 (default front), Injector 2 (default back), and Tray from the
rear panel. Save the plate and nuts so you can reinstall them to prevent
access to the high voltage area of the GC if you ever remove the ALS
interface board in the future.
12 Re- install the GC covers.

Accessories 4
Installing the G4515A Bar Code Reader/Mixer/Heater

If you have purchased a separate G4515A Bar Code Reader/Mixer/Heater
accessory, install it now. Otherwise skip this section.
Remove the sample tray from the GC

2 Park the sample tray by pressing the [P] button on the front tray panel.
4 Unplug the sample tray cable.
5 Unplug all injector cables.
6 Remove all vials from the injector turrets.
7 Remove all injectors from the GC inlet area. If desired, mount the
injectors on any available parking posts.
8 Remove all vial racks from the sample tray.
9 Completely remove the three T- 30 Torx screws securing the sample tray
to the mounting bracket.
10 Carefully remove the sample tray from the GC mounting bracket.

4 Accessories
Install the G4515A Bar Code Reader/Mixer/Heater

1 With the gantry in the far- left position, loosen the two T- 20 screws
securing the unknown vial station cover, and remove the plastic cover.
T-20 screws
Unknown vial station cover

Accessories 4
2 Slide the gantry towards the tray bracket as far as it will go.

4 Accessories
3 Loosen the T- 20 Torx screw and remove tray cover.
T-20 screw
4 Set the tray cover on a flat surface and remove the T- 10 Torx screw
that fastens the blanking plate to the tray cover. The blanking plate will

Accessories 4
fall to the surface below the tray cover when the screw is completely
removed.
T-10 screw

4 Accessories
5 Move the G4514- 60601 cable to the side.
G4514-60601 cable
6 Place the Bar Code Reader in the tray and secure with three screws.
3 screws

Accessories 4
7 Connect the BCR ribbon cable and power cable.
From tray
to BCR
From BCR
to tray

4 Accessories
8 Reinstall the tray cover. Make sure the tray cover edge does not pass
the outer housing edge. Push the tray cover towards the front of the
tray as far as possible before installing screws.
Outer housing edge
Tray cover edge

Accessories 4
9 Install the T- 20 Torx screw.
T-20 screw

4 Accessories
10 Install the self- tapping screw (0624- 0681) supplied with the BCR
accessory kit using a T- 10 Torx driver.
T-10 screw

Accessories 4
11 Slide the gantry to the opposite end of the tray, and replace the
unknown vial station cover.
T-20 screws
Unknown vial
station cover
12 Tighten the two T- 20 Torx screws to secure the unknown vial station
cover to the sample tray.
13 If you wish to install an optional 1/8- in ID heater vent line, remove the
bottom access panel on the underside of the sample tray using a T- 20
Torx driver. Otherwise, skip to the next section.
14 Remove the Heater Vent Base (G4515- 20532) using a straight blade
screwdriver.
15 Attach the 1/8- in ID vent line to the BCR, and route the vent tubing
out through the bottom access panel. Three wire saddles (1400- 3408)
and three M3 x 4 screws (0515- 0663) are provided to help route the
vent tubing.

4 Accessories
Installing the G4522A Heating and Cooling Plate

This section describes how to install the G4522A Heating And Cooling
Plate on the G4514A Sample Tray.
This section does not explain how to set up a water bath and pump.
You can control the temperature of the sample vials in the tray by
pumping temperature- controlled liquid through the heating and cooling
plate installed underneath the vial racks.
Ensure that the drainage tube is attached to the base of the sample tray. If possible,
CAUTION
remove any equipment from underneath the tray or take steps to protect any
equipment underneath the tray from potential leaks. When controlling for low sample
temperature with high ambient temperature or high humidity, water condensation from
the heating and cooling plate and sample tray could damage equipment under the
sample tray.
Tools needed
• Diagonal cutters
• T- 10 Torx driver
Remove the sample tray from the GC

2 Park the sample tray by pressing the [P] button on the front tray panel.
4 Unplug the sample tray cable.
5 Unplug all injector cables.
6 Remove all vials from the injector turrets.
7 Remove all injectors from the GC inlet area. If desired, mount the
injectors on any available parking posts.

Accessories 4
8 Remove all vial racks from the sample tray.

9 Completely remove the three T- 30 Torx screws securing the sample tray
to the mounting bracket.
10 Carefully remove the sample tray from the GC mounting bracket.
Install the heating and cooling plate

1 Make sure the gantry is in the park position (far- left, away from the
tray bracket).
2 Completely loosen the two T- 20 screws securing the unknown vial
station cover.
T-20 screws
Unknown vial station cover
3 Remove the unknown vial station cover.

4 Completely loosen the two T- 20 screws securing the unknown vial
station.

4 Accessories
5 Remove the unknown vial station.
Calibration post
6 Slide the gantry towards the home position (far- right, towards the tray
bracket).

Accessories 4
7 Loosen the T- 20 Torx screw securing the tray cover.
T-20 screw
Tray cover
8 Remove the tray cover.

9 Slide the gantry towards the park position (far- left, away from the tray
bracket).

4 Accessories
10 Loosen and remove the four screws securing the vial rack support
plate.
T-20 screws
Vial rack support

plate

Accessories 4
11 Remove the support plate by lifting the front of the plate and pulling
outward towards the front of the sample tray. The support plate will
slide out.

4 Accessories
12 Place the sample tray on its back and remove the bottom access panel
using a T- 20 Torx driver.
Cooling accessory plate
Bottom access panel
T-20 screw
13 Using a diagonal cutter, clip the metal tabs and remove the accessory
plate from the underside of the tray chassis.

Accessories 4
14 Place the sample tray on its base and position the heating and cooling
plate partially in place, leaving room to run the heating and cooling
plate cable out of the tray chassis through the bottom access opening.
Cable through bottom

access opening
Heating and cooling plate

4 Accessories
15 Once the cable is accessible through the bottom access opening, fit the
heating and cooling plate in place so the top is level with the tray
chassis.

Accessories 4
16 Secure the heating and cooling plate to the tray chassis using four
screws (two in front, two in back).
T-20 screws
Back of tray
T-20 screws

4 Accessories
17 Place the sample tray on its back and connect the heating and cooling
plate cable to the tray logic board (accessible through the bottom access
opening).
Connect cable
to tray board
18 Reinstall the bottom access panel.
Reassemble the sample tray

1 If necessary, slide the gantry to the home position (far- right, towards
the tray mount).
2 Replace the sample tray cover and secure it with a T- 20 Torx screw.
3 Slide the gantry to the park position (far- left, away from the tray
mount).
4 Replace the unknown vial station and secure it with two T- 20 Torx
screws.
5 Replace the unknown vial station cover and secure it with two T- 20
Torx screws.

Accessories 4
6 Install the heating and cooling plate vial racks. See “Installing the Vial
Racks” for details.
7 Install the sample tray on the GC. See “Installing the Sample Tray” for
details.
Install the drainage tubing

1 Connect the plastic tubing to the heating and cooling plate’s drainage
nipple on the back of the sample tray. The tubing must allow for the
heating and cooling plate to drain condensate easily with no back
pressure. Make sure that:
• The tubing slopes downward towards the drainage container.
• The tubing is kept straight without kinks that may block the flow.
• The open end of the tubing is not submersed in the drainage
container (Figure 32).

4 Accessories
• The tubing does not become clogged or dirty. Replace tubing if

necessary.
Figure 32 Drainage tube correctly hung (left) and incorrectly submersed (right)
2 Secure the tubing to the back of the heating and cooling plate using a
1/4- in Swagelok connection.
3 Check for any leaks before powering on the GC.
Complete the installation

1 Install the injectors. See “Installing the G4513A Injector” for details.
2 Connect the GC power cable, and power on the GC.
3 Calibrate the ALS system. See “Calibrating the ALS System” for details.
Coolant
Use only distilled water, ethylene glycol, or propylene glycol as coolant.

Accessories 4
Water bath and pump specifications
To limit burn hazards, the heating liquids should not exceed 60 ºC.
CAUTION
The water bath and pump system used to control the sample vial
temperatures must meet the following specifications:
• The components must meet national standards for safety requirements,
be suitable for unattended operation, be suitable for continuous
operation, and be controllable for high- temperature protection.
• The recommended coolant temperature range is 5 to 60 ºC
• If you use a built- in pump, it must be suitable for external circulation
of liquid and for connection of 1/4- in od (6.35 mm) tubing or larger.
• If you use a pressure pump, it must maintain a pressure from 1.5 to 2.5
psi.
• If you use a suction pump, the pump vacuum cannot exceed –4 psi.
• Typical recirculator cooling power capacity varies from 1000 to 2000
watts.
The temperature sensor detects the average coolant temperature in the heating and
NOTE cooling plate.

4 Accessories
Figure 33 Pressure vs. Water Flow

Part 3:
Operation
Introduction to Operation 113

Fast Injection 120
ALS Configuration 129
ALS Parameters 141
Syringes and Needles 153
Vials and Bottles 165
Running Samples 191

Interrupting a Run or Sequence 194

5
Introduction to Operation
Components 114
Features 116
Capabilities 119
Fast Injection 120
Solvent wash 122
Sample wash 122
Sample pump 122
Number and type of washes 122
This chapter describes the components that make up the Agilent 7693A
ALS, some of the important features of the system, and the sampler
capabilities.

About your 7693A Automatic Liquid Sampler
Components
The 7693A ALS system (Figure 34) can include:
• G4513A Injector module (one or two)
• G4514A Sample Tray (7890A GC, 6890 Series GC, 7820 MSD)
• G4515A Bar Code Reader/Mixer/Heater (BCR)
• G4517A ALS Controller (6890A GC)
• G4516A ALS Interface Board (6890 Plus GC)
• G4520A Sample Tray with pre- installed BCR/Mixer/Heater
• G4521A Enhanced Sample Handling Syringe Carriage
• G4522A Heating and Cooling Plate
• G4525A Set of 3 colored vial rack labels
• G4526A 7693A Upgrade Kit for 6890 Series GCs

Part 3, Operation
Figure 34 The 7693A ALS with 7890A GC and 5975 MSD

Part 3, Operation
Features
The key features of the ALS system include:
• Two interchangeable sample turrets provided with the injector:
• The standalone turret allows you to analyze up to 16 samples. It
holds two solvent positions and one waste bottle position. Two
sample positions can be alternately configured for sample
preparation. This turret is not compatible with the sample tray.
• The transfer turret is designed to work with the sample tray to
analyze up to 150 samples. The transfer turret has three sample vial
transfer locations; two of which are configurable for use in sample
preparation. There are six solvent A positions, four solvent B
positions, and five waste positions. This turret can be used with or
without the sample tray.
• Accessible solvent and waste vial capacity of 20 mL
• Ability to run sandwich injections with up to three sample layers
separated with air gaps
• A standard syringe carriage for syringes up to 100 µL
• An optional enhanced sample handling syringe carriage with a slow,
high- powered motor for syringes over 100 µL
• Cool on- column injections into 250- µm, 320- µm, and 530- µm columns
• An optional BCR/Mixer/Heater module
• An optional heating and cooling plate for the sample tray
• The ability to inject different sample amounts from different sample
vials
• The ability to interrupt a sequence to run priority samples, then resume
the sequence

Part 3, Operation
• Fast, slow, and variable plunger speeds under Agilent data system
control (Table 5 and Table 6)
The default values for variable plunger speeds are based on a 10 µL
syringe. You should reduce the injection speed to accommodate larger
syringe volumes. If you are performing a large volume injection and see a
plunger error, try slowing the inject rate.
Table 5 Fast/slow plunger speed as a function of syringe volume
Plunger Speed Syringe Volume (µL)

(µL/min)
0.5 1 2 5 10 25 50 100 250 500
Draw (µL/min)
Fast 15 30 60 150 300 750 1500 3000 300 600
Slow 15 30 60 150 300 750 1500 3000 300 600
Dispense (µL/min)
Fast 300 600 1200 3000 6000 15000 30000 60000 1500 3000
Slow 300 600 1200 3000 6000 15000 30000 60000 1500 3000
Inject (µL/min)
Fast 300 600 1200 3000 6000 15000 30000 60000
Slow 15 30 60 150 300 750 1500 3000 75 150

Part 3, Operation
Table 6 Variable plunger speed as a function of syringe volume
Variable Plunger Syringe Volume (µL)

Speed (µL/min)
(x) = Default value 0.5 1 2 5 10 25 50 100 250 500
Sample draw 1 - 30 1 - 60 1 - 120 1 - 300 1 - 600 1 - 1500 3- 6- 15 - 30 -

(15) (30) (60) (150) (300) (750) 3000 6000 15000 30000
(1500) (3000) (7500) (15000)
Sample dispense 1 - 300 1 - 600 1 - 1200 1 - 3000 1 - 6000 1- 3- 6- 15 - 30 -
(300) (600) (1200) (3000) (6000) 15000 30000 60000 150000 300000
(15000) (30000) (60000) (150000) (300000)
Injection 1 - 300 1 - 600 1 - 1200 1 - 3000 1 - 6000 1- 3- 6- 15 - 30 -

dispense (300) (600) (1200) (3000) (6000) 15000 30000 60000 150000 300000
(15000) (30000) (60000) (150000) (300000)
Solvent draw 1 - 30 1 - 60 1 - 120 1 - 300 1 - 600 1 - 1500 3- 6- 15 - 30 -

(15) (30) (60) (150) (300) (750) 3000 6000 15000 30000
(1500) (3000) (7500) (15000)
Solvent dispense 1 - 300 1 - 600 1 - 1200 1 - 3000 1 - 6000 1- 3- 6- 15 - 30 -

(300) (600) (1200) (3000) (6000) 15000 30000 60000 150000 300000
(15000) (30000) (60000) (150000) (300000)

Part 3, Operation
Capabilities
Table 7 summarizes the capabilities of the 7693A ALS.
Table 7 ALS capabilities
Parameter Range
Syringe size 1 to 500 µL
Wash mode A, B
A - A2, B - B2
A - A6, B - B4
Solvent saving 10%, 20%, 30%, 40%, 80% of syringe size (µL)
Injection volume 1 - 50% of syringe size (µL)
Sample pumps 0 - 15
Viscosity delay 0 - 7 seconds
Air gap 0 - 10% of syringe size (µL)
Pre-injection sample washes 0 - 15
Post-injection solvent A washes 0 - 15
Post-injection solvent B washes 0 - 15
Plunger speed Refer to Table 6 on page 118
Pre-injection solvent A washes 0 - 15

Pre-injection solvent B washes 0 - 15
Pre-injection dwell 0 - 1 minutes in .01 minute
Post-injection dwell 0 - 1 minutes in .01 minute
Sampling offset On, Off
Variable sampling depth position 2 mm below, 30 mm above
Multiple injection mode, number of injections 1 - 99
Multiple injection mode, injection delay time 0 - 100 seconds

Part 3, Operation
Fast Injection
This is a method of introducing a sample to a heated inlet without the
negative effect of needle fractionation.
If you are using the ALS for the first time, you may see some changes in
the resulting chromatograms. Most of the changes are due to reducing the
amount of vaporization from the needle during injection.
• The peak areas of your chromatograms may be smaller. Automatic fast
injection delivers the desired setpoint volume of sample. Without fast
injection, residual amounts of sample boil out of the needle and enter
the inlet. This extra amount could measure up to 1 µL.
• The peak areas of your chromatograms may show less differentiation
between the low boiling and high boiling components.
Without fast injection, the sample introduced is richer in low boiling
component than in high boiling components because of fractional
distillation in the needle. Not only does residual sample in the needle
enter the inlet, but the low boiling components boil off first. This is needle
fractionation or discrimination.

Part 3, Operation
Figure 35 compares manual injection with automatic fast injection from

the ALS for a 1- µL sample of C10 to C40 paraffins in hexane.
Automated injection
Manual injection
Figure 35 Automated vs. manual injection
For more information on the performance of the ALS, order the following
technical papers from your Agilent representative:
Publication No. 43- 5953- 1843:Snyder, W.Dale. Fast Injection with the
7673A Automatic Injector: Chemical Performance, Technical Paper 108,
June 1985.
Publication No. 43- 5953- 1878:Snyder, W.Dale. Performance Advantage of
the 7673A Automatic Injector Over Manual Injection, Technical Paper
109, August 1985.
Publication No. 43- 5953- 1879:Kolloff, R.H.C.Toney, and J.Butler.
Automated On- Column Injection with Agilent 7673A Automatic Injector
and 19245A On- Column Capillary Inlet: Accuracy and Precision,
Technical Paper 110, August 1985.

Part 3, Operation
Sample Carryover
Carryover is the presence of peaks from an earlier injection in the present
analysis.
The injector uses solvent washes, sample washes, and sample pumps to
control carryover. Each of these actions reduces the amount of sample left
in the syringe. The effectiveness of each depends on your application.
Solvent wash
The injector draws solvent into the syringe from either the solvent A
positions or solvent B positions, then discards the syringe contents into
one or more waste bottles. Solvent washes can occur before taking a
sample (pre- injection solvent wash) or immediately after the injection
(post- injection solvent wash). The volume of the wash can be adjusted.
Sample wash
During a sample wash, the injector draws the next sample into the syringe
and discards the contents into one or more waste bottles. Sample washes
occur before the injection. When sample is limited, you can use a solvent
prewash to wet the syringe before drawing sample. The volume of the
wash can be adjusted.
Sample pump
During a sample pump, the injector draws sample into the syringe and
returns it to the sample vial. Pumps occur after sample washes and
immediately before the injection. Pumps serve to eliminate bubbles. If the
needle contains solvent from a previous wash, the pump may add a small
amount of solvent that mixes with the sample and can dilute a small
volume.
Number and type of washes

Under ideal conditions, four default volume (80%) washes reduce the
carryover to one part in 10,000. The number and type of washes you need
depends on:
• The amount of carryover that you can accept
• The viscosity and solubility of the analyte(s)

Part 3, Operation
• The viscosity and volatility of the solvent(s)

• The degree of wear in the syringe barrel
• The wash volume
Chromatograms A and B (Figure 36) show the effect of carryover when
1 µL from a vial of methanol is injected after 1 µL from a vial of a solute
dissolved in methanol. The peaks in chromatogram B are from the solute
left in the syringe from the first injection.

Part 3, Operation
Chromatogram C shows the result of washing the syringe with four 80%
syringe volume solvent washes. The carryover peaks disappear.
Chromatogram A:
20 mg/mL of solute
in methanol
Chromatogram B:
Methanol blank
without washes
Chromatogram C:
Methanol blank
after four washes
Figure 36 Sample carryover

Part 3, Operation
Methods and Sequences

The sampler is usually controlled by a sequence, which is a list of samples
to be analyzed. It contains:
• Where to find the sample
• What method to use to analyze the sample
• How to measure and inject the sample
• How to generate a report of analysis
A method is a collection of setpoints (temperatures, times, etc.) that
controls the operation of a gas chromatograph.
The combination of a sequence and the methods it specifies provides
complete control over the analysis of your samples. However, the specific
details differ depending on the hardware and software used, so you are
referred to other documents for that information.
This discussion is limited to sampler- specific details. For setting up
methods and sequences see your Agilent data system help or GC
documentation.

Part 3, Operation
The Sampler Cycle

All versions of the ALS perform the same basic operations (Table 8).
Table 8 Sampler cycle
Step Action Notes
1 Transport the sample vial. • If necessary, move the sample vial

from the tray to the turret.
2 Wash the syringe with solvent. a Rotate a solvent bottle under the • The syringe can be washed several
syringe. times and with more than one
b Lower the syringe needle into the solvent. This is controlled by the
solvent. solvent pre-wash parameters.
c Draw in solvent.
d Raise the syringe needle out of the
solvent bottle.
e Rotate a waste bottle under the
syringe.
f Lower the syringe. Depress the
plunger to discard solvent.
g Raise the syringe needle out of the
waste vial.
3 Wash the syringe with sample. a Rotate the sample vial under the • The syringe can be rinsed with
syringe. sample several times.
b Lower the syringe needle so that the
needle pierces the vial septum and
enters the sample.
c Draw in sample.
d Raise the syringe and needle out of
the solvent bottle.
e Rotate a waste bottle under the
syringe.
f Lower the syringe needle. Depress
the plunger to discard sample.
g Raise the syringe needle out of the
waste vial.

Part 3, Operation
Table 8 Sampler cycle (continued)
Step Action Notes
4 Load the syringe with sample. a Rotate the sample vial under the • Actions c and d can be repeated
syringe. several times. The purpose is to
b Lower the syringe needle so that it expel air bubbles from the syringe.
pierces the vial septum.
c Draw in sample.
d With the needle still in the sample,
depress the syringe plunger quickly.
e After the final pump, draw in
sample.
f Raise the syringe needle out of the
sample vial.
5 Inject the sample. a Rotate the turret to expose the GC • Start signals are sent to the GC and
inlet. the data processor at the moment of
b Lower the syringe needle so that it injection.
pierces the inlet septum.
c Depress the syringe plunger to make
the injection.
d Raise the syringe needle out of the
GC inlet.
6 Wash the syringe with solvent. • Same as step 2, but according to the
post-injection parameters.
7 Transport the sample vial. • Return the sample vial to its initial
turret or tray location.
8 Perform repeat injections. • If so programmed, wait for the GC to

become Ready and repeat the cycle
from step 1.

Part 3, Operation

Part 3, Operation
6
ALS Configuration
7890A GC, 7820A GC, and 7820 MSD 130
6890 Series GC 131
6850 Series GC 133
7890A GC and 7820 MSD 135
6890 Series GC 137
This chapter describes how to configure the ALS using different

controlling devices.
The descriptions in this chapter refer to the features available with the GC
firmware and does not necessarily describe the capabilities available with
Agilent data systems. Refer to Agilent data system online help.

6 ALS Configuration
Configuring the Injector
7890A GC, 7820A GC, and 7820 MSD

For a 7890A GC, press [Config] [Front Injector] or [Config] [Back Injector] on
the GC keypad to display the front or back injector configuration
parameters. For a 7820A GC or 7820 MSD, press [Config] [Injector] on the
GC software keypad to display the front or back injector configuration
parameters.
CONFIGURE FRONT INJECTOR

Wash Mode Bottles 1 A, 1 B
Syringe Size 10.0
Wash Mode Bottles— This is only displayed when the injector has a
transfer turret installed. On a 7890A GC the turret solvent bottle positions
are selected using the [Mode/Type] key:
6-A and 4-B Washes—Uses all 6 solvent A bottles if injector uses
solvent A washes. Uses all 4 solvent B bottles if injector uses solvent B
washes. The injector alternates between all bottles.
2-A and 2-B Washes—Uses solvent bottles A and A2 if injector uses
solvent A washes and solvent bottles B and B2 if injector uses solvent
B washes. The injector alternates between all bottles.
1-A and 1-B Washes—Uses solvent bottle A if injector uses solvent A
washes and solvent bottle B if injector uses solvent B washes.
The injector always uses both WA waste bottles if a solvent A wash is
used and both WB waste bottles if a solvent B wash is used.
Syringe size— Enter a syringe size between 0.5 and 500 µL.
The GC assumes the syringe volume represents full plunger stroke. If the maximum volume
NOTE marked on the syringe barrel is halfway up the barrel, you will need to enter double that
volume (the label in this case is half of the full plunger stroke).

Part 3, Operation
ALS Configuration 6
6890 Series GC
Press [Config] [Front Injector] or [Config] [Back Injector] to display the
parameters.
Scroll to the desired parameter detailed below.
CONFIG F INJECTOR
Inject mode Normal
Wash mode A, B
Solvent saving Off
Syringe size 10.0

Injector Light On
Inject mode—Select the injection mode type that is installed on your

injector. On a 6890N GC the injection mode is selected using the
[Mode/Type] key:
Normal-Injects a single sample.
Sample + L2-Injects a mixture of two samples separated by an air
gap.
Sample + L2 + L3-Injects a mixture of three samples separated by
air gaps.
Large Volume-Injects sample using a 250 or 500 µL syringe.
Wash mode— This is only displayed when the injector has a transfer turret
installed. On a 6890N GC the turret solvent bottle positions are selected
using the [Mode/Type] key:
Wash using A, B—Uses solvent bottle A if injector uses solvent A
Use A-A2, B-B2—Uses solvent bottles A and A2 if injector uses solvent
A washes and solvent bottles B and B2 if injector uses solvent B
washes. The injector alternates between both bottles.
Use All A, B—Uses all 6 solvent A bottles if injector uses solvent A
washes. Uses all 4 solvent B bottles if injector uses solvent B washes.
The injector alternates between all bottles.

Part 3, Operation
6 ALS Configuration
For a 6890A or 6890 Plus GC, the wash mode is controlled by scrolling
through the options using the [On] key, or entering a value of:
• 1 for using solvent bottle A if injector uses solvent A washes and
solvent bottle B if injector uses solvent B washes.
• 2 for using solvent bottles A and A2 if injector uses solvent A washes
and solvent bottles B and B2 if injector uses solvent B washes. The
injector alternates between all bottles.
• 3 for using all solvent A bottles if injector uses solvent A washes and
all solvent B bottles if injector uses solvent B washes. The injector
alternates between all bottles.
The injector always uses both WA waste bottles if a solvent A wash is
used and both WB waste bottles if a solvent B wash is used.
Solvent Saving—Use this option to vary the syringe wash amount from
about 10% to 80% of syringe volume. This setting reduces the amount of
solvent and sample consumed during each injection cycle. See "Sample
Carryover" on page 122 for more information.
On a 6890N, the wash amount is selected using the [Mode/Type] key. This
brings up a selection of actual wash volumes based on the volume of the
syringe used. Select Off to disable solvent saving option.
For a 6890A or 6890 Plus, these settings are controlled by scrolling
through the options using the [On] key, or entering a setpoint value of:
• 0 to disable the solvent saving feature resulting in a wash volume equal
to 80% of syringe volume.
• 1 for 10% of syringe volume wash
Syringe size—Enter a syringe size between 0.5 and 500 µL.

Part 3, Operation
ALS Configuration 6
Injector Light—Control the LED light (On, Off) inside the injection
tower.
6850 Series GC
Use your Agilent data system to configure the injector for use.
Inject mode—Select the injection mode.
Normal-Injects a single sample (including large volume injections with
only one septum puncture).
Sample + L2-Injects a mixture of two samples separated by an air
gap.
Sample + L2 + L3-Injects a mixture of three samples separated by
air gaps.
Large Volume-Performs large volume injections using multiple septum
punctures (multiple injections per run).
Wash mode— This is only displayed when the injector has a transfer turret
installed.
Wash using A, B—Uses solvent bottle A if injector uses solvent A
Use A-A2, B-B2—Uses solvent bottles A and A2 if injector uses solvent
A washes and solvent bottles B and B2 if injector uses solvent B
washes. The injector alternates between both bottles.
Use All A, B—Uses all 6 solvent A bottles if injector uses solvent A
washes. Uses all 4 solvent B bottles if injector uses solvent B washes.
The injector alternates between all bottles.
Solvent Saving—Use this option to vary the syringe wash amount from
about 10% to 80% of syringe volume. This setting reduces the amount of
solvent and sample consumed during each injection cycle. See "Sample
Carryover" on page 122 for more information.
Syringe size—Enter a syringe size between 1 and 500 µL.

Part 3, Operation
6 ALS Configuration
Injector Light—Control the LED light (On, Off) inside the injection
tower.
5975T LTM-GC/MSD
Configure the injector using your Agilent data system. Refer to your data
system help for details.

Part 3, Operation
ALS Configuration 6
Configuring the Sample Tray

The sample tray delivers sample vials to the front and rear injectors
according to the defined sequence parameters. There is a separate set of
sequence parameters for each injector. The sample tray delivers vials to
the front injector before the rear injector. Stored sequences and bar code
configurations can be used to tell the sample tray where to deliver and
retrieve sample vials.
For the 7890A GC, press [Config] [Sample Tray] to access the sample tray and
Bar Code Reader setpoints. For the 7820 MSD, press [Config] [Sample Tray]
on the GC software keypad to display the sample tray configuration
parameters
CONFIGURE SAMPLE TRAY

BCR symbology Enable All
Enable checksum Off

Part 3, Operation
6 ALS Configuration
To edit the sample tray BCR symbology configuration, press [Config]

[Sample Tray] > BCR Symbology > [Mode/Status].
BCR SYMBOLOGY SELECT

Enable All
Enable 3 of 9
Enable Code 128
Enable Matrix 2 of 5
Enable Standard 2 of 5
Enable Interleaved 2 of 5
Enable UPC-A
Enable EAN/JAN 13
Enable EAN/JAN 8
Enable UPC-E
Press [Info] to view the possible values to enter.

BCR Symbology-Select one of the following bar code setpoints.
Enable All—The Enable All setting offers the greatest versatility for
laboratory use. It can encode both letters and numbers, plus a few
punctuation marks, and message length can be varied to suit both the
amount of data to be encoded and the space available.
Enable 3 of 9—The 3 of 9 setting can encode both letters and
numbers, plus a few punctuation marks, and message length can be
varied to suit both the amount of data to be encoded and the space
available.
Enable Code 128—The code 128 setting is used extensively worldwide.
It offers a full ASCII 128 symbol set with very dense code. The total
character set (14 if alphanumeric, 28 if numeric with starting code C)
includes a checksum digit.
Enable Interleaved 2 of 5—The 2 of 5 code is restricted to
numbers but does allow variable message length.

Part 3, Operation
ALS Configuration 6
Enable UPC-A—The Universal Product Code (UPC) is probably the most

well- known code in use today. UPC- A codes are 12 numbers (1 number
system, 10 data and 1 checksum) and have fixed message length.
Enable UPC-E—The Universal Product Code (UPC) is probably the most
well- known code in use today. UPC- E codes are 6 numbers (6 data)
and have fixed message length.
Enable EAN/JAN 13—The EAN/JAN 13 code offers 13 numbers (2
country, 10 data, 1 checksum).
Enable EAN/JAN 8—The EAN/JAN 8 code offers 8 numbers (2 country,
5 data, 1 checksum).
For more information on the Bar Code Reader, see "The G4515A Bar
Code Reader/Mixer/Heater" on page 23, "Installing the G4515A Bar
Code Reader/Mixer/Heater" on page 85, or its Operating Manual.
Enable checksum-Select one of the following checksum setpoints.
OFF-Disables the BCR checksum.
ON-Enables BCR checksum for 3 of 9 and 2 of 5.
Enable Tray Chiller-If installed, enable or disable the heating and
cooling plate temperature by turning it On or Off.
Tray Chiller Temp-If installed, the current heating and cooling plate
temperature is displayed. Sets the target heating and cooling plate
temperature.
Tray Chiller Error-band-If installed, set the allowable readiness of
detection of the temperature error band for the heating and cooling
plate temperature before it is declared not ready.
6890 Series GC
according to the defined sequence parameters. There are a separate set of

Part 3, Operation
6 ALS Configuration
Press [Config] [Sample Tray] to access the sample tray, Bar Code Reader, and
heating and cooling plate setpoints.
CONFIG SAMPLE TRAY

Use chiller rdy Off
BCR mode All
Enable checksum Off
To edit the sample tray BCR symbology mode, press [Config] [Sample Tray] >
BCR mode > [Mode/Status].
BCR SYMBOLOGY MODE

All symbologies
3 of 9
Code 128
Standard 2 of 5
Matrix 2 of 5
Interleaved 2 of 5
UPC-A
UPC-E
EAN/JAN 8
EAN/JAN 13

Use chiller rdy-If installed, enable or disable detection of the heating
and cooling plate temperature readiness. This feature is only available for
the 6890N GC.
For 6890A and 6890 Plus GCs, the chiller/heater temperature must be
manually monitored to determine readiness before running samples.

Part 3, Operation
ALS Configuration 6
Chiller err band-If the heating and cooling plate readiness

detection is enabled, set the allowable error band for the heating and
cooling plate temperature before it is declared not ready.
BCR mode-Select one of the following bar code setpoints.
All symbologies—The All symbologies setting offers the greatest
versatility for laboratory use. It can encode both letters and numbers,
plus a few punctuation marks, and message length can be varied to suit
both the amount of data to be encoded and the space available.
3 of 9—The 3 of 9 setting can encode both letters and numbers, plus a
few punctuation marks, and message length can be varied to suit both
the amount of data to be encoded and the space available.
Code 128—The code 128 setting is used extensively worldwide. It offers
a full ASCII 128 symbol set with very dense code. The total character
set (14 if alphanumeric, 28 if numeric with starting code C) includes a
checksum digit.
Interleaved 2 of 5—The 2 of 5 code is restricted to numbers but
does allow variable message length.
UPC-A—The Universal Product Code (UPC) is probably the most
well- known code in use today. UPC- A codes are 12 numbers (1 number
system, 10 data and 1 checksum) and have fixed message length.
UPC-E—The Universal Product Code (UPC) is probably the most
well- known code in use today. UPC- E codes are 6 numbers (6 data)
and have fixed message length.
EAN/JAN 8—The EAN/JAN 8 code offers 8 numbers (2 country, 5 data,
1 checksum).
EAN/JAN 13—The EAN/JAN 13 code offers 13 numbers (2 country, 10
data, 1 checksum).
For more information on the Bar Code Reader, see "The G4515A Bar
Code Reader/Mixer/Heater" on page 23, "Installing the G4515A Bar
Code Reader/Mixer/Heater" on page 85, or its Operating Manual.
Enable checksum-Enable or disable the checksum feature (On, Off).

Part 3, Operation
6 ALS Configuration

Part 3, Operation
7
ALS Parameters
7890A GC, 7820A GC, and 7820 MSD 143
6890 Series GC 146
6850 Series GC 148
7890A GC and 7820 MSD 149
6890 Series GC 150
This chapter describes how to set the automatic liquid sampler parameters
using different controlling devices.
The descriptions in this chapter refer to the features available with the GC
firmware and does not necessarily describe the capabilities available with
Agilent data systems. Refer to Agilent data system online help.

7 ALS Parameters
Setting the Injector Parameters

The available parameters depend on the specific configuration of your GC
and injector. Press the [Info] key to view the possible setpoint ranges for
each parameter. Refer to Table 7 on page 119 and Table 6 on page 118 for
ALS system capabilities.

Part 3, Operation
ALS Parameters 7
7890A GC, 7820A GC, and 7820 MSD

For a 7890A GC, press [Front Injector] or [Back Injector] on the GC keypad.
For a 7820A GC and 7820 MSD, press [Injector] on the software keypad.
Scroll to the desired setpoint detailed below.
Enter a setpoint value, use [Mode/Type] to change the selection, or turn
the setpoint on or off.
FRONT INJECTOR
Injection volume 1.00
Viscosity delay 0
Inject Dispense Speed 6000
Airgap Volume 0.20

Sample Pumps 6
Sample Washes 2
Sample Wash Volume 8
Solvent A post washes 0
Solvent A pre washes 0
Solvent A wash volume 8
Solvent B post washes 0
Solvent B pre washes 0
Solvent B wash volume 8
Sample Draw Speed 300
Sample Dispense Speed 6000
Pre dwell time 0
Post dwell 0
Sample offset 0
Injection Mode NORMAL
Tower LED ON
Injection volume—Sample volume to be injected. Enter the injection

volume in µL up to 50% of the configured syringe size. (Using a 10 µL
syringe, entries would be 0.1, 0.2, 0.3, and so forth up to 5 µL.) The GC
will round the volume to the next allowable parameter.

Part 3, Operation
7 ALS Parameters
Viscosity delay—How many seconds the plunger pauses at the top of

the pump and injection strokes to wait for the syringe to fill. For viscous
samples, the pause allows the sample to flow into the vacuum created in
the syringe.
Inject Dispense Speed—How many microliters per minute to inject.
Parameter value entered here rounds to the nearest acceptable parameter
value. For example, 7000 µL/min rounds to 7009 µL/min.
Airgap Volume—The amount of air separating the sample from the end of
the needle.
Sample pumps—How many times the syringe plunger is moved up and
down with the needle in the sample to expel air bubbles and improve
reproducibility.
Sample washes—How many times the syringe is rinsed with sample
before the injection. The injector lowers the syringe needle into the sample
vial, draws up sample, and empties it into one of the waste bottles.
Sample Wash Volume—How many microliters used for the sample wash.
Solvent A post washes—How many times the syringe is rinsed with
solvent from the solvent A (A1 through A6) bottles.
Solvent A pre washes—How many times the syringe is rinsed with
solvent from the solvent A (A1 through A6) bottles.
Solvent A wash volume—How many microliters used for the sample A
wash.
Solvent B post washes—How many times the syringe is rinsed with
solvent from the solvent B (B1 through B4) bottles.
Solvent B pre washes—How many times the syringe is rinsed with
solvent from the solvent B (B1 through B4) bottles.
Solvent B wash volume—How many microliters used for the sample B
wash.
Sample Draw Speed—The speed of the syringe plunger during sample
injection.
Sample Dispense Speed—If using a variable plunger speed, the speed of
the sample injection.

Part 3, Operation
ALS Parameters 7
Solvent Draw Speed—If using a variable plunger speed, the speed of the
syringe plunger during solvent injection.
Solvent Dispense Speed—If using a variable plunger speed, the speed
of the solvent injection.
Pre dwell time—How long, in minutes, the needle remains in the inlet
before the injection.
Post dwell—How long, in minutes, the needle remains in the inlet after
the injection.
Sample offset—Enables variable sampling depth.
Injection mode—The type of injection mode.
Injection Reps—If Injection mode is LVI with multiple reps, the amount
of repetitions.
Injection Delay—If Injection mode is LVI with multiple reps, the length
of delay between repetitions.
L2 volume—If Injection mode is a 2- layer or 3- layer Sandwich Injection,
the amount of sample used in layer 2.
L2 Airgap volume—If Injection mode is a 2- layer or 3- layer Sandwich
Injection, the amount of air used between sample layer 1 and sample layer
2.
L3 volume—If Injection mode is a 3- layer Sandwich Injection, the amount
of sample used in layer 3.
L3 Airgap volume—If Injection mode is a 3- layer Sandwich Injection, the
amount of air used between sample layer 2 and sample layer 3.
Tower LED—Control the LED light inside the injection tower.

Part 3, Operation
7 ALS Parameters
6890 Series GC
Press [Front Injector] or [Back Injector].
Enter a setpoint value, use the [Mode/Type] key, or turn the setpoint on or
off.
FRONT INJECTOR
Injection vol 1.00
#Sample pumps 6
Air gap 0.20
Viscosity delay 0
#Sample washes 0
#Solv A washes 0
#Solv B washes 0
Plunger speed FAST
Pre dwell time 0.00
Post dwell 0.00
Samp offset Off
#Solv A pre wash 0
#Solv B pre wash 0
Depending on the Inject mode set during injector configuration, the

following parameters may be available:
Injection volume/Sample volume—Sample volume to be injected.
Enter the injection volume in µL up to 50% of the configured syringe size.
(Using a 10 µL syringe, entries would be 0.1, 0.2, 0.3, and so forth up to
5 µL.) The GC will round the volume to the next allowable parameter.
Set the injection volume to Off to disable the injector tower.
L2 volume—Sample volume to be injected for sample layer 2.
L3 volume—Sample volume to be injected for sample layer 3.

Part 3, Operation
ALS Parameters 7
#Injection reps—For Large Volume injections. How many times the

syringe plunger is moved up and down with the needle in the sample to
expel air bubbles and improve reproducibility.
Injection delay—For Large Volume injections. How many seconds the
plunger pauses at the top of the pump and injection strokes. For viscous
samples, the pause allows the sample to flow into the vacuum created in
the syringe.
#Sample pumps—How many times the syringe plunger is moved up and
down with the needle in the sample to expel air bubbles and improve
reproducibility.
#L2 pumps—For 2- sample layer injections. How many times the syringe
plunger is moved up and down with the needle in the sample to expel air
bubbles and improve reproducibility.
#L3 pumps—For 3- sample layer injections. How many times the syringe
plunger is moved up and down with the needle in the sample to expel air
bubbles and improve reproducibility.
Air gap—The amount of air drawn after the sample.
L2 air gap—The amount of air drawn after sample layer 2.
L3 air gap—The amount of air drawn after sample layer 3.
Viscosity delay—How many seconds the plunger pauses at the top of
the pump and injection strokes. For viscous samples, the pause allows the
sample to flow into the vacuum created in the syringe.
#Sample washes—How many times the syringe is rinsed with sample
before the injection. The injector lowers the syringe needle into the sample
vial, draws up sample, and empties it into one of the waste bottles.
#Solvent A washes—How many times the syringe is rinsed with solvent
from the solvent A (A, A2, A3) bottles.
#Solvent B washes—How many times the syringe is rinsed with solvent
from the solvent B (B, B2, B3) bottles.
Plunger speed—The speed of the syringe plunger during injection.
Pre dwell time—How long, in minutes, the needle remains in the inlet
before the injection.

Part 3, Operation
7 ALS Parameters
Post dwell—How long, in minutes, the needle remains in the inlet after
the injection.
Samp offset—Enables variable sampling depth. Off disables the setpoint.
#Solvent A prewash—How many times the syringe is rinsed with solvent
before loading the syringe.
#Solvent B prewash—How many times the syringe is rinsed with solvent
before loading the syringe.
6850 Series GC
Set all parameters from your Agilent data system. Refer to your data
5975T LTM-GC/MSD
Set all parameters from your Agilent data system. Refer to your data

Part 3, Operation
ALS Parameters 7
Setting the Sample Tray Parameters

The available parameters depend on the specific configuration of your GC
and sample tray. Press the [Info] key to view the possible setpoint ranges
for each parameter. Refer to Table 7 on page 119 and Table 6 on page 118
for ALS system capabilities.

Press [Sample Tray].
Enter a setpoint value, use [Mode/Type] to change the selection, or turn
the setpoint on or off.
SAMPLE TRAY
Enable barcode Off
Enable vial heater Off
Enable mixer On
Mixing cycles 4
Mixing cycle time 1
Mixing speed 4000

Enable barcode-If installed, enable or disable the Bar Code Reader by
choosing On or Off.
Enable vial heater-If a BCR is installed, enable or disable the vial
heater by choosing On or Off.
Vial heater temp-If the vial heater is enabled, set the vial heating
temperature.
Vial heater time-If the vial heater is enabled, set the vial heating
time.

Part 3, Operation
7 ALS Parameters
Enable mixer-If a BCR is installed, enable or disable the mixer by

choosing On or Off.
Mixing cycles-If the mixer is enabled, set the number of mixing
cycles.
Mixing cycle time-If the mixer is enabled, set the mixing cycle time
in seconds.
Mixing speed-If the mixer is enabled, set the mixing speed in
revolutions per minute.
6890 Series GC
according to the defined sequence parameters. There are a separate set of
Press [Sample Tray].
Enter a setpoint value, use the [Mode/Type] key, or turn the setpoint on or
off.
SAMPLE TRAY
Enable tray On
Enable barcode On
BCR temp 28 Off

Mix cycles Off
Enable Tray—Turn On for a tray sequence, Off for sample bottles in the
injector turret.
Tray temp—Available if the heating and cooling plate is installed. Displays
the actual tray temperature.

Part 3, Operation
ALS Parameters 7
Tray temp target—Available if the heating and cooling plate is installed.

Set the tray target temperature.
Enable barcode—Available if the Bar Code Reader is installed. Turns the
Bar Code Reader on or off.
BCR temp—Displays the actual BCR heater temperature and defines the
BCR heater temperature setpoint.
Mix cycles—Defines the number of mix cycles.
For more information on the Bar Code Reader, see "The G4515A Bar Code
Reader/Mixer/Heater" on page 23, "Installing the G4515A Bar Code
Reader/Mixer/Heater" on page 85, or its Operating Manual.

Part 3, Operation
7 ALS Parameters

Part 3, Operation
8
Syringes and Needles
The injector uses syringes as the sample- handling device. This chapter
describes their properties and uses.

Selecting a Syringe
1 Select the syringe type based on the inlet you are using and the volume
of sample you want to inject.
Failure to use an on-column syringe when injecting into an on-column inlet could
CAUTION
damage the injector, syringe and column.
2 Select a syringe. Refer to the Agilent catalog for consumables and

supplies for part numbers and ordering information.
3 Select the appropriate syringe needle gauge (Table 9).
Table 9 Needle gauge selection
Inlet type Column type Needle gauge
Purged-packed, split or Any 23 gauge 

splitless (including MMI and Applicable 26s gauge or
PTV) 23/26s gauge tapered
Cool on-column 250 µm 26s/32 gauge tapered

320 µm 26s/32 gauge tapered
530 µm 23/26s gauge tapered or 26s
gauge

Part 3, Operation
Table 10 On-column autosampler syringes
Volume (µL) Description Unit Part No.
5 Removable needle, barrel only 5182-0836
Stainless steel needle for 530 µm column 3/pk 5182-0832
Stainless steel needle for 0.32 mm column 3/pk 5182-0831
Stainless steel needle for 0.25 mm column 3/pk 5182-0833
Plunger button 10/pk 5181-8866
Use syringe needles with a conical tip. Do not use sharp- tipped needles.
They tear the inlet septum and cause leaks. Also, a sharp- tipped needle
tends to wipe off on the septum as it exits resulting in a large solvent tail
on the chromatogram (Figure 37 and Figure 38).
Sharp tip Cone tip
Figure 37 Needle tips

Part 3, Operation
Needle tips
Tapered needle
Figure 38 Needle shapes

Part 3, Operation
Inspecting a Syringe
Before installing a syringe:
1 Roll the syringe on the edge of a clean flat surface. If the tip of the
needle moves in a circle, straighten the shaft by bending it slightly near
where it connects to the syringe barrel and check it again (Figure 39).
Bend here if necessary
Figure 39 Inspecting the syringe
2 Check for a rough needle. The needle surface may have closely spaced
concentric ridges that act like a miniature file and abrade pieces of the
septum into the inlet or vial. The ridges are easy to see under 10X
magnification.
If there are ridges, polish the needle by pulling it through a folded
piece of fine emery paper between your finger and thumb until the
ridges are gone. Be careful not to modify the tip of the syringe.
3 Check for a sticky plunger. Slide the plunger of the syringe up and
down a few times. It should move smoothly without sticking or binding.
If it is sticky, remove the plunger and clean it with solvent.

Part 3, Operation
Installing a Syringe
To install a syringe (Figure 40):
Plunger carrier
Slide
Plunger screw
Syringe carrier Plunger
Flange guide Flange
Syringe latch Barrel
Needle
Needle support foot
Figure 40 Installing a syringe
1 Unplug the injector cable, and if desired, mount the injector on a

parking post, or lay the injector tower on a work bench.
3 Slide the syringe carriage to the top position.
4 Open the syringe latch by swinging it in a counterclockwise direction.
5 Lift the plunger carrier to the top position.
6 Carefully pass the syringe needle through the guide hole in the needle
support foot.

Part 3, Operation
7 Align the syringe flange with the flange guide and press the syringe
into place, keeping the needle end in the guide hole of the needle
support foot. Make sure that the flat edge of the syringe flange faces
out (Figure 41).
Failure to correctly install the syringe flange into the flange guide will result in damage to
NOTE the syringe plunger.
Flange
Flange guide
Figure 41 Syringe flange orientation
8 Close the syringe latch by swinging it clockwise until it snaps in place.

9 Loosen the plunger screw entirely by turning it counterclockwise until
the stop is reached.
10 Slide the plunger carrier down until it is completely over the syringe
plunger, and tighten the plunger thumb screw until finger- tight.
11 Manually move the plunger carrier up and down. If the syringe plunger
does not move along with the carrier, repeat the previous steps until
installed correctly. Be sure the plunger thumb screw is secure and tight.
If the carrier is not completely attached to the syringe plunger it may
become detached after a few injections.

Part 3, Operation
Repeating this movement can damage the syringe.

CAUTION
12 Verify that the needle is inside the guide hole of the needle support
foot. The needle should be straight and pass freely through the needle
guide hole.
If the needle is bent or is outside the guide hole, remove the syringe
and reinstall. See Figure 42 for a properly installed syringe.
Syringe latch (closed)
Needle support foot
Figure 42 Syringe carriage and needle support with syringe installed

Part 3, Operation
14 Do the following only if the injector tower was removed from the
mounting post during installation:
a If necessary, plug in the injector cable.
b Install the injector on the mounting post. See “Installing the G4513A
Injector" on page 43 for details.
c If you have a sample tray, calibrate the ALS system. See “Calibrating
the ALS System" on page 229 for details.

Part 3, Operation
Removing a Syringe
To remove a syringe:
parking post.
4 Completely loosen the plunger thumb screw until it reaches the stop,
and lift the plunger carrier off of the syringe plunger.
Be careful not to bend the syringe needle. Only pull the syringe out of the carriage until
CAUTION
clear. The needle bends easily when still seated in the needle support guide.
6 Carefully pull the top of the syringe out of the flange guide, then lift
the needle out of the needle support foot.
To install a syringe, see “Installing a Syringe" on page 203 for details.

Part 3, Operation
Replacing a Syringe Needle

The stainless steel needles used for 250- µm and 320- µm injections must
be inserted into a glass syringe barrel. Select the correct size needle for
the column you will use.
Needles for 250- µm injections have silver- colored stops. Needles for
320- µm injections have gold- colored stops. See your Agilent consumables
and supplies catalog or the Agilent web site (www.agilent.com/chem) for a
list of syringes and needles.

Part 3, Operation
To insert a needle into a syringe barrel (Figure 43):
Plunger
Barrel
PTFE disk
Stop
PTFE disk Needle

Needle
Spring
Cap
Figure 43 Syringe parts
1 Unscrew the syringe barrel cap and remove the spring.

2 Make sure the needle has a PTFE disk (Figure 43). If the syringe
barrel does not have the PTFE disk, use the instructions in the syringe
box to wrap the needle yourself.
3 Slide the spring and the cap down over the needle.
4 Insert the needle into the syringe barrel.
5 Screw the cap back on the syringe barrel.

Part 3, Operation
9
Vials and Bottles
Select a sample vial 166
Select a vial septa 167
Fill a sample vial 169
Label a sample vial 168
Cap a sample vial 170
Select the bottles 172
Fill the solvent bottles 173
Prepare the waste bottles 173
This chapter describes sample vials, solvent bottles, and waste bottles,
including how to place them in the tray or turret. It also discusses how to
estimate the maximum number of samples that can be run before solvent
bottles must be refilled or waste bottles must be emptied.

9 Vials and Bottles
Preparing a Sample Vial
Select a sample vial

The injector and sample tray use clear or amber glass sample vials with
crimp caps, or screw- cap vials. Use amber glass vials for light- sensitive
samples. Refer to your Agilent catalog for consumables and supplies for
acceptable vial types. Incompatible sample vials cause tray and turret
errors.
Figure 44 shows the critical dimensions for sample vials used with the
7693A ALS system. These dimensions do not make up a complete set of
specifications.
Body Diameter (BD) = 11.7 ± 0.2

Cap Diameter (CD) = BD × 1.03 maximum
All dimensions in millimeters
CD
6.25 ± 0.25
3.7 minimum
8.2±± 0.2
8.2 0.2
33.5 ± 1.5
Vial plus cap 32 ± 0.5
height 25 minimum
body height
11.7 ± 0.2
BD
Maximum height of a capped vial Crimp cap sample vial
Figure 44 Sample vial dimensions

Part 3, Operation
Vials and Bottles 9
Select a vial septa

There are two types of septa used with crimp caps and screw- on caps,
each with different resealing characteristics and different resistance to
solvents.
• One type is natural rubber formulation coated with PTFE on the
sample side. This septum is suitable for samples with a pH range of 4.0
to 7.5. They are less resistant to solvents after puncture and are more
easily cored than silicone rubber septa. Coring may deposit septum
pieces in the vial and affect your chromatograms.
• Another is high- quality, low- extractable silicone rubber septa, coated
with PTFE on one or both sides. They are more resistant to solvents
after puncture and to coring by the needle.
Refer to your Agilent catalog for consumables and supplies for more
information.
Figure 45 shows the diameter for vial cap apertures.
4.65 mm (0.183 in.) minimum 5.58 mm (0.220 in.) recommended
Figure 45 Vial cap aperture specifications

Part 3, Operation
9 Vials and Bottles
Label a sample vial

Some vials are available with a write- on spot for easy marking. If you
choose to make and apply your own labels, Agilent Technologies
recommends the positioning and maximum label thickness shown in
Figure 46.
No label 13.2 maximum

or tape Text areas are optional
Overlap Text
mismatch
1.0 3.6 minimum Bar code
maximum Text
26.6 maximum
13.4 minimum 16.4 ± 0.5

No label or tape
Label skew
12.56
All dimensions are Maximum width
in millimeters measured at overlap
Figure 46 Sample vial label dimensions
Correct sample vial dimensions are critical for proper gripper operation. Vials and labels
CAUTION
that do not meet these specifications may cause sampler errors. Service calls and
repairs found to be due to vials and microvials that do not meet these specifications
are not covered under warranty or the service contract.

Part 3, Operation
Vials and Bottles 9
Fill a sample vial

Figure 47 shows the recommended fill volumes for sample vials of:
• 1 mL for the 2- mL vial
• 50 µL for the 100- µL vial
The air space in the vial is necessary to avoid forming a vacuum when
sample is withdrawn. This could affect reproducibility.
Do not inject air into the vials to prevent this vacuum. This often damages the cap seal
CAUTION
and may damage syringe needles.
1 mL 50 µL
3.6 mm* 2-mL vial 100-µL vial
* Needle position based on default sampling depth.
Figure 47 Recommended fill volumes for sample vials
When developing your method, keep the following in mind:

• If you need to test a large amount of sample over repeated injections,
divide the sample among several vials to obtain reliable results.
• When sample volume in the vial is low, contaminants from the previous
sample injection or solvent washes may have a greater impact on the
sample.
If you change suppliers, you may need to redevelop your method. Differing
manufacturing practices for vial hardware sometimes cause variances in
your results.

Part 3, Operation
9 Vials and Bottles
Cap a sample vial
If using a sample vial with a screw cap top, be sure to completely tighten the screw cap
CAUTION
before use.
Handle
Adjuster screw
Jaws
Crimp cap
Sample vial
Figure 48 Crimping caps
To install the airtight crimp caps:

1 Clean the inside surfaces of the crimper jaws.
2 Place the crimp cap over the top of the vial.
3 Lift the vial into the crimper. Squeeze the handle until it reaches the
adjuster screw.

Part 3, Operation
Vials and Bottles 9
Figure 49 shows acceptable and unacceptable vial caps.
Centered Off-center
No folds or wrinkles Folds and wrinkles
Acceptable Unacceptable
Figure 49 Acceptable and unacceptable caps
Check each vial for proper crimping:

1 Be sure there are no folds or wrinkles on the part of the cap that
wraps under the neck of the vial. To remove folds or wrinkles, turn the
vial about 10° and crimp it again. Adjust the crimper for a looser crimp
by turning the adjusting screw clockwise.
2 The cap should be finger- tight. If the cap is loose, adjust the crimper
for a tighter crimp by turning the adjusting screw counterclockwise.
Crimp the cap again. If the cap is too tight, the septum will distort and
the vial may leak.
3 Be sure that each cap has a flat septum centered over the top of the
vial.
• If the septum is not flat, remove the cap, turn the crimper adjusting
screw clockwise, and try again.
• If the cap is not centered, remove the cap and make sure the new
cap is flat on the top of the vial before you squeeze the crimper.

Part 3, Operation
9 Vials and Bottles
Preparing Solvent and Waste Bottles

The solvent bottles hold solvent for rinsing the syringe between injections.
The injector dispenses the solvent washes and sample washes into waste
bottles. The number of samples that can be analyzed may be limited by
the wash or waste bottle capacity.
Select the bottles

Solvent and waste bottles can be closed with either diffusion caps (a
plastic cap with a hole; it retards evaporation while letting the needle
enter freely) or septa. Agilent Technologies recommends diffusion caps
(Figure 50) over septa for two reasons:
• The diffusion cap allows multiple entrances into a bottle without
contaminating the liquid inside the bottle with small pieces of septum
material.
• For common solvents, the rate of diffusion out of the bottle is less with
a diffusion cap than with a septum that has been punctured multiple
times with a standard syringe needle.
Diffusion cap (recommended)
Minimum solvent level
Figure 50 Four milliliter bottle used for solvent or waste

Part 3, Operation
Vials and Bottles 9
Fill the solvent bottles

Rinse and fill each solvent bottle with 4 mL of fresh solvent. The liquid
level will be near the shoulder of the bottle. Good laboratory practice
dictates using no more than 2.0 mL of the 4 mL solvent for syringe
washes. The needle tip draws solvent 18.5 mm from the bottom of the vial
(Figure 51).
4-mL fill volume

2.0 mL usable solvent volume
MINIMUM SOLVENT LEVEL
18.5 mm 2-mL solvent remains
Figure 51 Needle tip position when withdrawing solvent
Prepare the waste bottles

Empty and rinse each waste bottle after each multiple vial run. The
syringe can discard about 4 mL of waste into the waste bottle (Figure 52).
4-mL maximum waste
Figure 52 Needle tip position when discharging waste

Part 3, Operation
9 Vials and Bottles
Placing Vials and Bottles in the Turret

Two turrets are provided with the G4513A injector (Figure 53). The
16- sample standalone turret, and the 3- sample transfer turret.
A 1 A L1
B 2 A2 L2
W 3 A3
L3
16 L3 4 A4
15 L2 5 A5 WB
14 6 A6 WB
13 7 B WA
12 8 B2 WA
11 10 9 B3 B4 WA
Standalone turret Transfer turret
(16 samples) (3 samples)
Top views.
Figure 53 Injector turrets
The labeled positions are defined in Table 12 and Table 13.
Table 12 Standalone turret labels
Position Label Bottle/Vial
1 through 14 1 through 14 Sample vials
15 15 Sample vial

L2 Layer 2 bottle

L3 Layer 3 bottle
17 W Waste bottle
18 B Solvent B bottle
19 A Solvent A bottle

Part 3, Operation
Vials and Bottles 9
Table 13 Transfer turret labels
1 L1 Dedicated vial transfer position A 

Layer 1 bottle
2 L2 Configurable vial transfer position B

Layer 2 bottle
3 L3 Configurable vial transfer position C

Layer 3 bottle
4 and 5 WB Waste B1 - B2 bottles
6 through 8 WA Waste A1 - A3 bottles
9 through 12 B - B4 Solvent B1 - B4 bottles
13 through 18 A - A6 Solvent A1 - A6 bottles
With a sample tray

You must use the transfer turret. Place up to 150 samples in the three
vial racks, according to the programmed sequence. Figure 54 shows tray
loading for a sequence that uses tray positions 6 through 21.
150 110 100 60 50 20 10

19 9
18 8
17 7
16 6 First vial in
15 position 6
14
13
12
141 101 91 51 41 21 11 1
Last vial in
position 21
Figure 54 Loading tray positions

Part 3, Operation
9 Vials and Bottles
Without a sample tray

You can place up to sixteen vials, a solvent A, a solvent B, and a waste
bottle in the standalone turret. If you use the transfer turret, you can load
three sample vials and the solvent and waste bottle capacity increases to
15 (Figure 53).

Part 3, Operation
Vials and Bottles 9
Using Two Injectors (7890A and 6890 Series GCs Only)

With two injectors mounted on the GC, you can use the front injector, the
back injector, or both injectors simultaneously.
Two- injector configurations have the following characteristics:
• The system sends one injector ready signal to the GC when both
injectors are ready and one start signal at the beginning of the injection
stroke.
• The two injectors inject simultaneously.
With a sample tray

Set run parameters for each injector in the sequence. When you set up the
run parameters, you must identify which data channel is for which
injector on a 7890A or 6890 Series GC.
• When using a 7890A or 6890 Series GC for sampler control, you assign
the channel when you set up the sequence.
• When using the Agilent ChemStation for sampler control, you assign the
channel when defining the instruments.
When both injectors have samples, they begin the injection cycle together,
including any sample washes. After they have completed the specified
sampling steps, they inject the samples. After the injection, both injectors
go through the solvent wash cycle. When both injectors are done, the tray
picks up the sample vial from the front injector and returns it to its
original position on the tray, then picks up the vial from the back injector
and returns it to its original position.
Without a sample tray

The injectors go through the same motions as with a sample tray. The
injectors inject samples from position 1 first, followed by samples from the
remaining sample vial positions. If the two injectors do not have the same
number of samples, the injector that completes its sequence first remains
idle while the other finishes.

Part 3, Operation
9 Vials and Bottles
How Many Sample Vials Can I Run?

The number of sample vials that you can run at one time is determined by
the following parameters for your application:
• The number of sample injections per sample vial.
• The syringe size used: 1 µL to 500 µL.
• The syringe wash volume (Table 14)
• The number of solvent washes (both pre- and post- injection) required
from each solvent bottle.
• The number of sample washes and solvent washes per sample injection
that the injector discards into each waste bottle.
• Number of waste bottles.
Table 14 Syringe wash volumes
Syringe Size  80% syringe 40% syringe 30% syringe 20% syringe 10% syringe
(µL) volume µL volume µL volume µL volume µL volume µL
1 0.8 0.4 0.3 0.2 0.1
2 1.6 0.8 0.6 0.4 0.2
5 4 2 1.5 1 0.5
10 8 4 3 2 1
25 20 10 7.5 5 2.5
50 40 20 15 10 5
100 80 40 30 20 10
250 200 100 75 50 25
500 400 200 150 100 50

Part 3, Operation
Vials and Bottles 9
Solvent bottle equation (injector)
The number of sample vials given by these equations are estimates. Solvent
CAUTION
characteristics such as evaporation rate and surface tension may affect the capacity of
the bottles.
This equation estimates the maximum number of sample vials you can run
from one solvent bottle.
Maximum number of sample vials per solvent bottle
2000
=
VW x NSI x NSW
where:
VW = Volume of Wash in L taken from Table 14
NSI = Number of sample injections taken from each sample vial
NSW = Number of Solvent washes (pre and post) per sample injected
Waste bottle equation

This equation estimates the maximum number of sample vials you can run
per one waste vial type (A orB).
Maximum number of sample vials per waste bottles used (WA or WB)
VWaste
= x W
WWash x NSI x NSS
where:
VWaste = Volume of waste bottles used in L. Use 4000.

Part 3, Operation
9 Vials and Bottles
VWash = Volume of wash in µL taken from Table 14

NSI = Number of sample injections taken from each sample vial
NSS = Total number of pre- and post- solvent A or solvent B washes and
sample washes per sample injected. When using both solvent A and B,
the sample wash is divided evenly between all four waste bottles in the
1- sample turret
W = Waste vial usage.
Standalone, W = 1
Transfer, W = 3 for waste A, W = 2 for waste B
Example
A tray is installed with a 3- sample transfer turret in the injector. Your
application parameters are:
• Two injections per vial
• Three washes from solvent bottle A
• Two washes from solvent bottle B
• Two sample washes
• 10- µL syringe
• 80% wash volume (default)
1 Substitute the parameters of your application into the solvent bottle
equation:
For Solvent A
VW = 8 from Table 14
NSI = 2
NSW = 3
2000
= = 41
8 x 2 x 3

Part 3, Operation
Vials and Bottles 9
For Solvent B
VW = 8 from Table 14
NSI = 2
NSW = 2
2000
= = 62
8 x 2 x 2
2 Substitute the parameters of your application into the waste bottle

equation:
For Waste A
VWaste = Use 12000 for the 3- sample transfer turret
VWash = 8 from Table 14
NSI = 2
NSS = 3 (solvent A washes) + 1 (Sample wash) = 4
Maximum number of sample vials per waste bottles used (WA)
12000
= = 187.5
8 x 2 x 4
For Waste B
VWaste = Use 8000 for the 3- sample transfer turret
VWash = 8 from Table 14
NSI = 2
NSS = 2 (solvent B washes) + 1 (sample wash) = 3
Maximum number of sample vials per waste bottles used (WB)

Part 3, Operation
9 Vials and Bottles
8000
= = 166
8 x 2 x 3
3 Analyze the results keeping the following in mind:

• The 3- sample transfer turret has 3 waste A bottles and 2 waste B
bottles. If solvent A is used, all waste A bottles must be used. If
solvent B is used, all waste B bottles must be used.
• Sample washes are evenly distributed to all waste bottles used.
• The injector can be configured to use 1 A, 1 B; 2 A’s, 2 B’s; or all 6
A’s and 4 B’s.
Using a single solvent bottle of each type, all five waste bottles must be
used; 41 vials can be run. Using two solvent A bottles and two solvent B
bottles, 84 vials can be run. If you use three solvent A bottles and three
solvent B bottles, you can run 150 vials which is the tray capacity limit.
We strongly recommend that all waste positions in all turrets contain bottles at all
CAUTION
times, regardless of which ones are actually used in the current configuration. This
protects against accidental discharge of solvent into the turret body, which could
damage it.

Part 3, Operation
Vials and Bottles 9
Reduced solvent and sample usage

Solvent and sample washes by default use 80% of the syringe capacity.
Solvent and sample can be conserved by reducing this volume. This is
done by configuring each injector’s solvent saving setting.
PTFE-tipped syringes must be used to lubricate the barrel wall. Standard syringes, will
CAUTION
fail quickly with limited lubrication.
The solvent wash can be set to use less than the usual 80%. This modifies
the solvent wash process as follows:
1 The syringe draws in solvent to the percent specified, which can be as
little as 10% of the syringe size.
2 The syringe and needle rise out of the solvent bottle.
3 The plunger rises to the 80% mark, rinsing the syringe barrel with
solvent, followed by air.
4 The solvent and air are discharged into a waste bottle.
Confirm that sample carryover (see “Sample Carryover”) is not a problem
with the reduced solvent washes.

Part 3, Operation
9 Vials and Bottles
Sandwich Injections
The ALS system has the ability to draw liquid from multiple vials to
create multilayered, or sandwich, injections. Each layer of sample, internal
standard, or solvent can be separated by a layer of air (from 0% to 10% of
the syringe size). Figure 55 and Figure 56 show examples of 2- and 3- layer
sandwich injections.
Air gap 1 Air gap 2
Layer 1 (L1) Layer 2 (L2)
Figure 55 2-layer sandwich injection
Air gap 1 Air gap 2 Air gap 3
Layer 1 (L1) Layer 2 (L2) Layer 3 (L3)
Figure 56 3-layer sandwich injection

Part 3, Operation
Vials and Bottles 9
When loading vials for sandwich injections, layer 1 (L1) can be placed in
any turret position 1- 14 if using a standalone turret, or in any tray
position 1- 150 if using a transfer turret with sample tray. The vials for
layer 2 (L2) and layer 3 (L3) must be placed in turret positions L2 and L3
(Figure 57), respectively.
A 1 A L1
B 2 A2 L2
W 3 A3
L3
16 L3 4 A4
15 L2 5 A5 WB
14 6 A6 WB
13 7 B WA
12 8 B2 WA
11 10 9 B3 B4 WA
Figure 57 Turret vial locations for sandwich injections
For the following examples, we assume the use of a 7890A GC with a

front injector and sample tray. Refer to “Setting the Injector Parameters”
for more information.

Part 3, Operation
9 Vials and Bottles
Example 2-layer sandwich injection

Suppose you want to create a 2- layered sandwich injection using 2.0 µL of
sample and 15 µL of solvent separated by 0.10 µL air gaps (Figure 58).
Air gap 1 Air gap 2

(0.10 µL) (0.10 µL)
Sample (L1) Solvent (L2)

(2.0 µL) (15 µL)
Figure 58 Example 2-layer sandwich injection with 2.0 µL of sample and 15 µL of sol-
vent
1 Place the sample vial (L1) in tray position 1.

2 Place the solvent vial (L2) in turret position L2.
3 Press [Front Injector] on the GC keypad.
4 Scroll to Injection Mode and select 2-LAYER.
5 Set the following parameters for the front injector:
• Injection volume—2.0 µL
• Airgap Volume—0.10 µL
• L2 volume—15 µL
• L2 Airgap Volume—0.10 µL
Note that for 2- and 3- layer injection modes, Injection volume and Airgap
volume represent layer 1 (L1) parameters.
6 Store the method parameters:
a Press [Method] on the GC keypad.
b Scroll to an available method number.
c Press [Store] to select the method number.
d Press [Yes] to confirm.

Part 3, Operation
Vials and Bottles 9
7 Set up the sandwich injection sequence:

a Press [Seq] on the GC keypad.
b Scroll to Method # under Subseq 1 and press [On/Yes].
c Enter the method number from step 6 using the GC numeric keypad,
and press [Enter] to confirm the entry.
d Scroll to Samples and press [1] [.] [1] to set the vial range on the
sample tray, and press [Enter] to confirm the entry.
8 Run the sandwich injection sequence:
a Press [Seq control] on the GC keypad.
b Scroll to Start sequence and press [Enter]. The sandwich injection
sequence begins.

Part 3, Operation
9 Vials and Bottles
Example 3-layer sandwich injection

Suppose you want to create a 3- layered sandwich injection using 10 µL of
solvent A, 2.0 µL of sample, and 15 µL of solvent B separated by 0.10 µL
air gaps (Figure 59).
Air gap 1 Air gap 2 Air gap 3

(0.10 µL) (0.10 µL) (0.10 µL)
Solvent A (L1) Sample (L2) Solvent B (L3)

(10 µL) (2.0 µL) (15 µL)
Figure 59 Example 3-layer sandwich injection with 10 µL of solvent A, 2.0 µL of sam-

ple, and 15 µL of solvent B
1 Place the solvent A vial (L1) in tray position 1.

2 Place the sample vial (L2) in turret position L2.
3 Place the solvent B vial (L3) in turret position L3. Refer to Figure 57
on page 185 for turret position information.
4 Press [Front Injector] on the GC keypad.
5 Scroll to Injection Mode and select 3-LAYER.
6 Set the following parameters for the front injector:
• Injection volume—10 µL
• Airgap Volume—0.10 µL
Note that for 2- and 3- layer injection modes, Injection volume and Airgap
volume represent layer 1 (L1) parameters.

Part 3, Operation
Vials and Bottles 9
7 Store the method parameters:

a Press [Method] on the GC keypad.
b Scroll to an available method number.
c Press [Store] to select the method number.
d Press [Yes] to confirm.
8 Set up the sandwich injection sequence:
a Press [Seq] on the GC keypad.
b Scroll to Method # under Subseq 1 and press [On/Yes].
c Enter the method number from step 7 using the GC numeric keypad,
and press [Enter] to confirm the entry.
d Scroll to Samples and press [1] [.] [1] to set the vial range on the
sample tray, and press [Enter] to confirm the entry.
9 Run the sandwich injection sequence:
a Press [Seq Control] on the GC keypad.
b Scroll to Start sequence and press [Enter]. The sandwich injection
sequence begins.

Part 3, Operation
9 Vials and Bottles

Part 3, Operation
10
Running Samples
Injection volume 192
Sampler response to interruptions 194
Restarting an interrupted sequence 194
This chapter describes the process for running one or more samples.

10 Running Samples
Running a Sample
When running a sample, keep your hands away from the syringe needle. The needle
WA R N I N G
is sharp and may contain hazardous chemicals.
To operate your automatic liquid sampler:

1 Install a clean syringe. See “Installing a Syringe" on page 158.
2 Fill the solvent bottles. See “Preparing Solvent and Waste Bottles" on
page 172.
3 Place the solvent and waste bottles in the turret. See “Placing Vials and
Bottles in the Turret" on page 174.
4 Load the sample vials into the turret or the tray. See “Preparing a
Sample Vial" on page 166.
5 Prepare the GC sequence. See your GC or ChemStation documents.
6 Run the sequence by pressing the start button on the GC. When the GC
is ready, the ALS begins the injections.
Injection volume
The injection volume depends on the sample size and the syringe size.
• Syringe size may be 1 L, 2 L, 5 L, 10 L, 25 L, 50 L, or 100 L
for the standard syringe carriage.
• Syringe size may be 250 µL or 500 µL for the enhanced sample
handling syringe carriage.
• Sample size may be 1- 50% of the syringe size in 1% increments.

Part 3, Operation
Running Samples 10
Using the ALS Controller

When the ALS controller is on a 6890A GC:
• [Start] on the G4517A ALS Controller is disabled.
• Pressing [Start] on the 6890A GC starts the sequence.
• Pressing [Stop] on the G4517A ALS Controller stops the ALS controller
sequence, and if the GC is waiting for a signal from the controller to
start a run, an error message is displayed on the GC. To resume the
sequence, see the following section on “Restarting an interrupted
sequence" on page 194.

Part 3, Operation
10 Running Samples
Interrupting a Run or Sequence

The following events interrupt a run:
• Power failures—The power to the GC or controlling device fails.
• Stop commands—[Stop] on the GC is pressed, or the Stop Run/Abort
option is selected from the Agilent ChemStation.
• Safety or operator faults—The sampler recognizes these fault(s):
• The injector door was opened
• Turret error
• Plunger error
• Tray arm axis error
• The injector was moved on the GC during injection
• The tray failed to deliver a vial
Sampler response to interruptions

If the interruption was caused by a problem that the sampler recognizes,
a message appears on the GC or Agilent ChemStation. The 6890A, and
6890 Plus GCs do not display sampler messages. For more information, see
“Error Messages" on page 238.
• Power failure—Aborts the run. Restart the sequence (see below).
• Stop commands—Interrupts the run. Restart the sequence (see below).
• Safety or operator faults—Aborts the run. Restart the sequence (see
below).
Restarting an interrupted sequence

To restart an aborted sequence from the point of interruption:
1 Resolve the problem that caused the interruption.
2 The tray automatically moves any unknown vials found in the gripper
arms or in an unexpected location to the unknown vials station.
3 The tray automatically starts the run with the next vial in the
sequence.
This allows normal operation to continue after an interruption without
delaying the entire sequence.

Part 3, Operation
Running Samples 10
Running a Priority Sample

Priority samples are for 7890 and 6890 Series GCs only.
If the Use priority parameter is on in your GC sequence, the sample tray
checks for a vial in position 150 before loading a new vial into the
injector turret. If it finds a vial there, it loads that sample vial into the
turret and runs it according to the method you assigned for priority
samples.
When the priority sample run is completed, it returns the priority sample
vial to tray position 149, therefore keeping position 150 empty when using
this feature. The tray gripper again checks vial position 150 and, if there
is no vial there, continues your original sequence from where it was
interrupted. For more information on how to program priority sequences,
see your 6890 GC documentation.

Part 3, Operation
10 Running Samples

Part 3, Operation
Part 4:
Maintenance and Troubleshooting
Maintenance 199
Faults and Errors 233
Faults 234
Error Messages 238
Troubleshooting 243

Replacement Parts 253
G4513A Injector 254

11
Maintenance
The information in this chapter will assist you in keeping the sampler
running smoothly.

11 Maintenance
Periodic Maintenance
This section contains some suggestions for ensuring good performance of
your Automatic Liquid Sampler system. The maintenance interval varies
with the use of the instrument.
Do not use any lubricants on the Automatic Liquid Sampler. They may affect the
CAUTION
chemical performance of the GC and damage the instrument.
When cleaning the instrument, as described below, use a damp (not wet!), lint-free
CAUTION
cloth. Do not use chemical cleaners.
On an occasional basis:
✔ Calibrate the ALS system. See “Calibrating the ALS System” on
page 229 for details.
✔ Clean the gantry, tray base, vial racks, turrets, and other surfaces.
✔ Wipe away any excess spill remains from the spill tray found
underneath the turret. See “Removing the turret” on page 210 for
details.
✔ Clean the needle support foot and nearby surfaces on the injector. Dust
and dirt accumulate in these areas and can be picked up by the syringe
needle and carried into the inlet.
✔ Inspect the needle support foot for signs of wear, and replace if
necessary. See “Replacing the Needle Support Foot” on page 213 for
details.
✔ Clean the injector surfaces and door.
✔ Vacuum any dust found on or around the vents on the injector or tray.
✔ Make sure the injector mounting post is tight.
✔ Make sure the tray mounting screws are tight.
✔ Make sure the mounting bracket screws are tight.

Part 4, Maintenance and Troubleshooting
Maintenance 11
✔ Be sure all cables are securely connected.

✔ If using a liquid heating and cooling plate, the drainage tubing must
allow any condensate to drain easily with no back pressure. Make sure
that:
• The tubing slopes downward towards the drainage container.
• The tubing is kept straight without kinks that may block the flow.
• The open end of the tubing is not submersed in the drainage
container.
• The tubing does not become clogged or dirty. Replace tubing if
necessary.

11 Maintenance
Tray Home and Park Positions
Figure 60 Tray in Park position
Figure 61 Tray in Home position

Maintenance 11
Installing a Syringe
To install a syringe (Figure 62):
Plunger carrier
Slide
Plunger screw
Syringe carrier Plunger
Flange guide Flange
Syringe latch Barrel
Needle
Needle support foot
Figure 62 Installing a syringe

parking post, or lay the injector tower on a work bench.
5 Lift the plunger carrier to the top position.
6 Carefully pass the syringe needle through the guide hole in the needle
support foot.

11 Maintenance
7 Align the syringe flange with the flange guide and press the syringe
into place, keeping the needle end in the guide hole of the needle
support foot. Make sure that the flat edge of the syringe flange faces
out (Figure 63).
Failure to correctly install the syringe flange into the flange guide will result in damage to
NOTE the syringe plunger.
Flange
Flange guide
Figure 63 Syringe flange orientation
8 Close the syringe latch by swinging it clockwise until it snaps in place.

9 Loosen the plunger screw entirely by turning it counterclockwise until
the stop is reached.
10 Slide the plunger carrier down until it is completely over the syringe
plunger, and tighten the plunger thumb screw until finger- tight.
11 Manually move the plunger carrier up and down. If the syringe plunger
does not move along with the carrier, repeat the previous steps until
installed correctly. Be sure the plunger thumb screw is secure and tight.
If the carrier is not completely attached to the syringe plunger it may
become detached after a few injections.

Maintenance 11
Repeating this movement can damage the syringe.

CAUTION
12 Verify that the needle is inside the guide hole of the needle support
foot. The needle should be straight and pass freely through the needle
guide hole.
If the needle is bent or is outside the guide hole, remove the syringe
and reinstall. See Figure 64 for a properly installed syringe.
Syringe latch (closed)
Needle support foot
Figure 64 Syringe carriage and needle support with syringe installed

11 Maintenance
14 Do the following only if the injector tower was removed from the
mounting post during installation:
a If necessary, plug in the injector cable.
b Install the injector on the mounting post. See “Installing the G4513A
Injector” on page 43 for details.
c If you have a sample tray, calibrate the ALS system. See “Calibrating
the ALS System” on page 229 for details.

Maintenance 11
Removing a Syringe
To remove a syringe:
parking post.
4 Completely loosen the plunger thumb screw until it reaches the stop,
and lift the plunger carrier off of the syringe plunger.
Be careful not to bend the syringe needle. Only pull the syringe out of the carriage until
CAUTION
clear. The needle bends easily when still seated in the needle support guide.
6 Carefully pull the top of the syringe out of the flange guide, then lift
the needle out of the needle support foot.
To install a syringe, see “Installing a Syringe” on page 203 for details.

11 Maintenance
Changing the Turret

Two turrets are provided with the G4513A injector (Figure 65). The
16- sample standalone turret, and the 3- sample transfer turret.
A 1 A L1
B 2 A2 L2
W 3 A3
L3
16 L3 4 A4
15 L2 5 A5 WB
14 6 A6 WB
13 7 B WA
12 8 B2 WA
11 10 9 B3 B4 WA
(16 samples) (3 samples)
Top views.
Figure 65 Injector turrets
The labeled positions are defined in Table 15 and Table 16.
Table 15 Standalone turret labels
1 through 14 1 through 14 Sample vials

L2 Layer 2 bottle

L3 Layer 3 bottle
17 W Waste bottle
18 B Solvent B bottle
19 A Solvent A bottle

Maintenance 11
Table 16 Transfer turret labels
1 L1 Dedicated vial transfer position A 

Layer 1 bottle
2 L2 Configurable vial transfer position B

Layer 2 bottle
3 L3 Configurable vial transfer position C

Layer 3 bottle
4 and 5 WB Waste B1 - B2 bottles
6 through 8 WA Waste A1 - A3 bottles
9 through 12 B - B4 Solvent B1 - B4 bottles
13 through 18 A - A6 Solvent A1 - A6 bottles
To change your turret, use the following instructions for proper

replacement.
1 Remove all vials from the turret.
2 Unplug the injector cable and place the injector tower on a parking
post.
4 Remove the syringe. See “Removing a Syringe” on page 207.
5 While holding the turret in place with your hand, completely loosen the
three T- 10 Torx screws that fasten the turret cap to the motor hub.
6 Remove the turret cap.
7 Rotate the turret to the home position (with the turret injector opening
facing the injector carriage).
8 Lift the turret off of the motor hub, then slide out. Avoid contact with
the injector tower when removing the turret.

11 Maintenance
Turret cap
Turret cap arms
Turret
Turret injector
opening
Figure 66 Removing the turret
9 Rotate the motor hub so the tabs on the motor hub face outward.
Motor hub tabs
Motor hub

Maintenance 11
10 Reinstall the turret. Align the inner groove on the turret with the motor
hub tabs, then slide the turret onto the motor hub. The turret should
sit flat on the hub.
11 Reinstall the turret cap. Align the turret cap arms with the turret
injector opening and place the turret cap in place.
Turret injector
opening
Turret cap arms
12 Tighten the three T- 10 Torx screws.

13 Install the syringe. See “Installing a Syringe” for more information.
15 Remove the injector tower from the parking post and install the injector
on the mounting post. See “Installing the G4513A Injector“ for details.
16 Plug in the injector cable.
17 When powered on, the injector verifies the turret type. A fault light will
show if the turret is not installed correctly.
18 Align the injector. See “Aligning the Injector” on page 225 for details.
19 If you installed a transfer turret and are using a sample tray, then you
must calibrate your ALS system. See “Calibrating the ALS System” on
page 229 for details.

11 Maintenance
Adapting for Cool On-Column Injection

The 7693A injectors can inject samples directly into 250- m, 320- m, and
530- m columns in GCs with a cool- on- column inlet.
When performing cool on- column injections, the injector:
• Slows the carriage speed so the overall injection time increases to
500 milliseconds.
• Lowers the tip of the syringe needle an additional 19 mm into the
column.
To adapt the injector and GC for cool on- column use, follow these steps:
1 If necessary, remove the current syringe from the injector. See
“Removing a Syringe” on page 207 for more information.
2 If necessary, remove the injector from the mounting post and unplug
the injector cable. If desired, park it on a parking post.
3 Select the on- column syringe needed for the column size. See your
Agilent catalog for consumables and supplies, your GC operating
documentation, and the Agilent web site (www.agilent.com/chem) for a
list of parts.
4 Replace the needle support foot with the supplied on- column foot. See
“Replacing the Needle Support Foot” on page 213 for more information.
5 Install the on- column syringe. See “Installing a Syringe” on page 203
for more information.
6 Prepare the GC inlet. See your GC operating documentation for
instructions.
• Check your needle to column size.
• Verify that the insert matches the needle size.
• If necessary, replace the septum.
For a list of other consumables needed to perform these injections, see
your GC operating documentation.
7 Plug in the injector cable.
8 Install the injector on the mounting post. See “Installing the G4513A
Injector“ for details.

Maintenance 11
Replacing the Needle Support Foot

You must use either the standard needle support foot (Figure 67) or the
on- column needle support foot depending on the type of injection.
Standard needle guide
On-column needle guide
Figure 67 Replacing the needle support foot
Replace the needle support foot when you change injection types or when
the support foot shows signs of wear:
2 Remove the syringe. See “Removing a Syringe” on page 207 for details.
3 Slide the syringe carriage up to the top position.
4 Completely remove the T- 10 Torx screw from the support foot. Be
careful to not let the screw fall into the turret assembly.
5 Slide off the support foot.
6 Slide on the new support foot.
7 Replace the T- 10 Torx screw and tighten.

11 Maintenance
8 Install the appropriate syringe. See “Installing a Syringe” on page 203

for details.

Maintenance 11
Adapting for Syringes Over 100 µL

The injectors can perform enhanced sample handling injections using
syringes over 100 µL. To adapt the injector and GC for enhanced sample
handling injections, follow these steps:
1 If necessary, remove the current syringe from the injector. See
“Removing a Syringe” on page 207 for details.
2 Replace the standard syringe carriage assembly with the G4521A
Enhanced Sample Handling Syringe Carriage assembly. See “Replacing
the Syringe Carriage Assembly” on page 216 for details.
3 Replace the needle support foot with the appropriate enhanced sample
handling injection support foot. See “Replacing the Needle Support
Foot” on page 213 for details.
4 Install the appropriate syringe. See “Installing a Syringe” on page 203
for details.
5 If necessary, reinstall the injector on the GC. See “Installing the G4513A
Injector“ for details.
7 If you have a sample tray, calibrate the ALS system. See “Calibrating

11 Maintenance
Replacing the Syringe Carriage Assembly

Use the standard syringe carriage assembly (Figure 68) for injections up
to 100 µL, and the G4521A Enhanced Sample Handling Syringe Carriage
(Figure 69) for injections over 100 µL.
Figure 68 Standard syringe carriage assembly

Maintenance 11
Figure 69 Enhanced Sample Handling syringe carriage assembly
To replace the syringe carriage assembly:

1 Remove all vials and bottles from the turret, and disconnect the injector
cable from the GC.
2 If desired, remove the injector from the mounting post and mount the
injector tower on a parking post.
4 Remove the syringe. See “Removing a Syringe” on page 207 for details.
5 Remove the turret. See “Changing the Turret” on page 208 for details.
6 Slide the syringe carriage assembly down until the assembly cable is
accessible below the tower casing, and detach the cable from the
assembly.

11 Maintenance
7 Completely loosen and remove the T- 10 Torx screw at the top of the
syringe carriage assembly.
T-10 Torx screw

Maintenance 11
8 Slide the syringe carriage assembly completely up until the flange and
latch are accessible.
Plunger carrier
Syringe carriage
Cable Flange
T-10 Torx screw

Latch
Figure 70 Removing the syringe carriage assembly

11 Maintenance
9 Completely loosen and remove the T- 10 Torx screw above the syringe
latch.
T-10 Torx screw
10 Carefully remove the syringe carriage assembly from the injector

carriage.
11 Slowly position the replacement syringe carriage assembly on the
injector carriage. The syringe carriage assembly will hang in place when
positioned correctly.
12 Completely tighten the T- 10 Torx screw above the syringe latch.

Maintenance 11
13 Slide the syringe carriage assembly completely down until the cable
input jack on the assembly is accessible below the injector casing.
Cable input jack

11 Maintenance
14 Completely tighten the T- 10 Torx screw at the top of the syringe

carriage assembly.
T-10 Torx screw
15 Connect the assembly cable to the syringe carriage assembly.

16 Slide the syringe carriage assembly completely up.
17 Make sure you have the appropriate needle support foot installed. See
“Replacing the Needle Support Foot” on page 213 for details.
18 Install the turret. See “Changing the Turret” on page 208 for details.
19 Install the syringe. See “Installing a Syringe” on page 203 for details.
21 If necessary, plug in the injector cable and install the injector tower on
the mounting post. See “Installing the G4513A Injector“ for details.
23 If you have a sample tray, calibrate the ALS system. See “Calibrating

Maintenance 11
Replacing a Syringe Needle

The stainless steel needles used for 250- µm and 320- µm injections must
be inserted into a glass syringe barrel. Select the correct size needle for
the column you will use.
Needles for 250- µm injections have silver- colored stops. Needles for
320- µm injections have gold- colored stops. See your Agilent consumables
and supplies catalog or the Agilent web site (www.agilent.com/chem) for a
list of syringes and needles.

11 Maintenance
To insert a needle into a syringe barrel (Figure 71):
Plunger
Barrel
PTFE disk
Stop
PTFE disk Needle

Needle
Spring
Cap
Figure 71 Syringe parts
1 Unscrew the syringe barrel cap and remove the spring.

2 Make sure the needle has a PTFE disk (Figure 71). If the syringe
barrel does not have the PTFE disk, use the instructions in the syringe
box to wrap the needle yourself.
3 Slide the spring and the cap down over the needle.
4 Insert the needle into the syringe barrel.
5 Screw the cap back on the syringe barrel.

Maintenance 11
Aligning the Injector

This section explains how to perform the injector alignment procedure.
The injector has been factory- aligned prior to shipment. The alignment
procedure should only be run if the injector hardware configuration has
changed or if the Align Mode light comes on.
Agilent does not recommend performing this procedure unless the Align Mode light turns
NOTE on. It is not necessary to align the turret after changing turrets.
If the top, orange Align Mode light is on, the injector will not operate
again until the alignment procedure has successfully completed.
To align the injector:
1 Remove all vials from the turret.
2 Open the injector door and remove the syringe. See “Removing a
Syringe” on page 207 for details.
4 Use a long, narrow object to press the recessed Alignment button above
the indicator lights. Avoid contact with anything behind or around the
button inside the recessed hole (Figure 72).
Alignment button
Align Mode
Fault
Ready
Figure 72 Aligning the injector

11 Maintenance
The orange Align mode light is on during the alignment procedure:

a The turret rotates to verify that the syringe was removed, then
rotates to determine what type of turret is installed.
b The syringe carriage moves all the way down, homes, then moves
back up again.
c The syringe carriage steps down until it touches the turret. This sets
its position relative to the turret.
d The plunger moves to calibrate stops.
e The syringe carriage moves down and the turret rotates to set its
position relative to the syringe carriage position.
If any of these steps fail, the process will halt and the fault light will shine. If it halts at step
NOTE b, confirm that the turret is installed correctly and press the Alignment button again. If it
fails again, unplug the injector, reconnect it, and try one more time before obtaining Agilent
service.
5 When the injector stops and the green Ready light is on, the calibration
is finished.
If this alignment was user- initiated (orange Align Mode light was off
before pressing the Alignment button) and alignment fails, unplug the
injector, reconnect it, and it will reset to the old alignment values.
6 Open the injector door and install the syringe. See “Installing a
Syringe” on page 203 for details.

Maintenance 11
Aligning the Sample Tray

This section explains how to perform the sample tray alignment
procedure. The sample tray has been factory- aligned prior to shipment.
The alignment procedure should only be run if the Align Mode light comes
on.
Agilent does not recommend performing this procedure unless the Align Mode light turns
NOTE on or if Agilent support requests it to be performed.
If the left, orange Align Mode light is on, the sample tray will not operate
again until the alignment procedure has successfully completed.
To align the sample tray:
1 Use a long, narrow object (such as a pen tip) to press the recessed
Alignment button to the left of the indicator lights. Avoid contact with
anything behind or around the button inside the recessed hole
(Figure 73).
Alignment button
Align Mode
Fault
Ready
Figure 73 Align the sample tray
The orange Align mode light blinks during the following steps:
a The gripper power calibrates.
b The gantry calibrates the X, Y, and Z home and span settings.
c The gantry is zeroed to calibration position (X, Y, Z).

11 Maintenance
If any of these steps fail, the process will halt. Press the Alignment button again. If it fails
NOTE again, unplug the sample tray, reconnect it, and try one more time before obtaining Agilent
service.
2 When the sample tray stops in the Home position and the green Ready
light is on, the calibration is finished.
If this alignment was user- initiated (orange Align Mode light was off
before pressing the Alignment button) and alignment fails, unplug the
sample tray, reconnect it, and it will reset to the old alignment values.

Maintenance 11
Calibrating the ALS System

The ALS system calibration process aligns the sample tray with the
injector turret position so vial transfers occur without incident.
Calibration should be performed if a calibration does not exist, and also
as a routine maintenance procedure.
Calibrating the ALS system is recommended if any ALS components are
moved.
To calibrate your ALS system:
1 Place the calibration vial (G4514- 40588) in tray position 1 (Figure 74).
Figure 74 Tray position 1

11 Maintenance
2 Remove any vials from transfer turret positions L1, L2, and L3 for all
installed injectors (Figure 75).
L1
L2
L3
Figure 75 Transfer turret positions L1, L2, L3 (top view)
3 Start the ALS system calibration:

• On a 7890A GC, use the GC front keypad and select [Options]
Calibration > ALS > Start Calibration.
• On a 6890 Series GC, use the GC front keypad and select [Options]
Calibration > Sample tray > Start Calibration.
The following calibration process will occur for all installed injectors:
a The tray assesses the turret alignment by placing the calibration vial
into turret position L1 and returning to sample tray position 1.
b The tray tests the vial height and turret position by using the
alignment tab between positions L1 and L2 on the transfer turret.
c The tray verifies the turret alignment by placing the calibration vial
into turret position L1 and returning it to sample tray position 1.
4 When the calibration process is complete, the green Ready status light
will come on and the gantry will stop in the Home position (Figure 61
on page 202).
Remember to replace any vials that were moved for the calibration
process.

Maintenance 11
Replacing Power Fuses in the G4517A ALS Controller

The G4517A ALS Controller uses two replaceable fuses to protect its
electronics from line voltage problems. If blown, replace them as described
below.
Fuses blow for a reason. The most likely cause at first installation is an incorrect power
CAUTION
configuration (see “Verify the power configuration” on page 80). Otherwise, normal
operation should not blow the fuses. If the fuses blow frequently, identify and correct
the problem
1 Turn off the controller.

2 Remove the power cord.
3 Remove the fuse holder module using a small, flat- bladed screwdriver.
(See “Installing the G4526A/G4517A ALS Controller (6890A GCs)” for
details.)
4 Pull the tab out using a small, flat- bladed screwdriver.
5 Remove the fuses.
6 Install the new fuses (Figure 76).
2 A 250 VAC
V
250 PE T A
TY A 2
2
Tabs
2 A 250 VAC
Figure 76 Proper fuse orientation

11 Maintenance
7 Push the tabs closed.

8 Reinstall the fuse holder module, making sure the orientation is correct
for the line voltage input. See “Installing the G4526A/G4517A ALS
Controller (6890A GCs)” for details.

12
Faults and Errors
Faults 234
Injector faults 234
Sample tray faults 236
Error Messages 238
Sometimes things do not work as expected. In most cases, the nature of

the problem is signalled either by status lights on the injector and sample
tray or by error messages on the GC display. If this happens, use this
chapter to discover the probable cause and the corrective action to take.

Faults
Injector faults
The injector status is indicated by the three lights on the front injector
panel (Figure 77).
Align Mode light

Fault light
Ready light
Figure 77 G4513A Injector status lights
During normal operation, the green Ready light is on. If the injector is
busy, the green Ready light is flashing.
If another combination of lights is on, an error has occurred.
Use the information in this chapter to try to solve or identify the problem
before obtaining Agilent service.
Table 18 Injector status lights
Lights Possible cause Action
All lights are off. • The line voltage to the GC is off. 1 Verify the injector is properly
• The injector cable or connected to the GC.
connection to the GC is bad. 2 Check the power source for your
• Your GC requires service. GC.
3 Obtain Agilent service.

Table 18 Injector status lights (continued)
Fault light is on. • The injector door is open. 1 Ensure that the injector door is
• Injector is not properly closed.
mounted to the GC. 2 If the fault light stays on, obtain
Agilent service.
3 Ensure that the injector is
mounted properly. For more
information, see “Installing the
G4513A Injector” on page 43.
4 Ensure the correct mounting post
is installed. See “Installing the
G4513A Injector” on page 43.
5 If the Fault light stays on, obtain
Agilent service.
Fault light is flashing • Syringe error. 1 Re-install or replace the syringe.

two times.
Fault light is flashing • Turret error. 1 Re-install the turret.

three times.
Fault light is flashing • Plunger error.

four times.
Align Mode light is on. • The system was not initialized. 1 Verify the turret is properly
• There is an injector memory installed. See “Changing the
error. Turret” on page 208.
2 Perform the alignment procedure
to initialize the system. See
“Aligning the Injector” on
page 225.
3 If alignment fails, obtain Agilent
service.
Align Mode light is • Customer pushed the align 1 The alignment and calibration
flashing. mode button. process is currently underway.
Let the process finish.
All lights are on. • There is a board failure. 1 Check all cable connections.
• There is a firmware revision 2 Turn the instrument off, then on
conflict. again.
3 If the lights remain on, obtain
Agilent service.

Table 18 Injector status lights (continued)
All lights are flashing. • Wrong driver board installed. 1 Install the correct driver board.
2 Check firmware revision.
3 If lights remain flashing, obtain
Agilent service.
Sample tray faults

The sample tray status is indicated by the three lights on the front panel
(Figure 78).
Align Mode light

Fault light
Ready light
Figure 78 G4514A Sample Tray status lights
During normal operation, the green Ready light is on. If the sample tray is
busy, the green Ready light is flashing.
If another combination of lights is on, an error has occurred.
Use the information in this chapter to try to solve the problem before
obtaining Agilent service.

Table 19 Tray status lights
All lights are off. • The device is unplugged.
Fault light is on. • System fault.
Fault light is flashing • A vial is lost or missing.

one time.
Fault light is flashing • X-axis error.

two times.
Fault light is flashing • Y-axis error.

three times.
Fault light is flashing • Z-axis error.

four times.
Fault light is flashing • Gripper error.

five times.
Align Mode light is on. • The system was not initialized. 1 Perform the alignment procedure
• There is a tray memory error. to initialize the system. See
“Aligning the Injector” on
page 225.
2 If alignment fails, obtain Agilent
service.
Align Mode light is • Customer pushed the align 1 The alignment and calibration
flashing. mode button. process is currently underway.
Let the process finish.
All lights are on. • There is a board failure. 1 Check all cable connections.
• There is a firmware revision 2 Turn the instrument off, then on
conflict. again.
3 If the lights remain on, obtain
Agilent service.
All lights are flashing. • Wrong driver board installed. 1 Install the correct driver board.
2 Check firmware revision.
3 If lights remain flashing, obtain
Agilent service.

Error Messages
Table 20 lists the sampler error messages as reported on the GCs. Error
messages are not displayed on 6890A or 6890 Plus GCs. If you receive an
error message that is not shown below, record it. Make sure that your GC
is properly configured and that your sample vials and equipment match
your method and/or sequence. If the problem continues, report your error
message to Agilent service.
Table 20 Error messages
Message Probable cause Suggested action
Bottle in gripper • The sample vial was not delivered 1 Remove the vial and return it to its
properly and stayed in the tray position in the tray.
gripper. 2 Ensure that the vial racks are
snapped into place.
3 Ensure that the injector is plugged
into the correct connector on the
back of the GC. For 6890, ensure it is
configured properly. See
“Connecting the Cables” on
page 55.
4 Check the deliver to location for the
vial and verify that the location is
empty and free from obstructions.
5 Make sure that the injector is
upright/vertical on the GC.
6 Restart the sequence.
7 If the error occurs again, obtain
Agilent service.
Front (or Back) door open or Injector • See “Faults” on page 234.
not mounted
Front (or Back) injector com error • There is a communications error • Obtain Agilent service.
between the injector and the GC.

Table 20 Error messages (continued)
Front (or Back) injector incomplete • The syringe needle is bent. 1 See “Correcting Syringe
injection • The plunger or syringe carriage is Problems” on page 251.
operating incorrectly during 2 Remove the syringe from the
injection. injector and check the plunger for
stickiness or binding. Replace the
syringe if necessary.
Agilent service.
Front (or Back) injector reset • There is an interruption in the power • Obtain Agilent service.
supply from the GC.
Front (or Back) plunger error • The syringe plunger is sticking or 1 Remove the syringe and check it for
not securely connected to the plunger stickiness or binding.
plunger carrier. Replace the syringe if necessary. For
• The plunger solenoid is binding. more information, see “Inspecting a
• The plunger carrier encoder is Syringe” on page 157.
inoperable. 2 Check the viscosity of the sample
against the viscosity parameter.
Reset the viscosity parameter if
necessary.
Agilent service.
Front (or Back) syringe error • The syringe carriage motor is 1 Ensure the syringe is installed
defective. correctly. For more information, see
• The syringe is not currently installed “Installing a Syringe” on page 158.
or is an incorrect type. 2 Ensure the syringe meets
• The syringe carriage sensor is specifications.
inoperable. 3 If the syringe needle is bent, see
“Correcting Syringe Problems” on
page 251.
Agilent service.

Front (or Back) turret error • Something has interfered with the 1 Clear any obstructions.
turret rotation. 2 Check the Align Mode light. If it is
• The turret motor/encoder assembly on, perform the alignment
is inoperable. procedure. See “Aligning the
• The turret type was changed while Injector” on page 225.
the power was on and the turret 3 Tighten the top of the turret.
alignment procedure was not 4 If the error occurs again, obtain
performed. Agilent service.
• Turret is loose.
Injector not present • There is a board failure in the 1 Make sure that the injector-to-GC
injector or GC. cable connection is secure.
• The injector cable is bad or not 2 Check your method to make sure it
securely connected to the GC. uses the appropriate injector
• There is a cable failure in the GC. location.
• Your method specifies an incorrect 3 If the error remains, obtain Agilent
injector location (method service.
mismatch).
Injector offline • There is a board failure in the 1 Make sure that the injector to GC
injector or GC. cable connection is secure.
• The injector cable is bad or not 2 If the error remains, obtain Agilent
connected. service.
• There is a cable failure in the GC.
No Bar Code Reader • Bar Code Reader cable not securely 1 Ensure the Bar Code Reader cable
connected. connection is secure.
• Bar Code Reader is defective. 2 If the problem continues, obtain
• Tray is defective. Agilent service.
No bottle in gripper • The sample vial was not found by 1 Make sure that the sample vials are
the gripper. in the locations specified by the
• The gripper could not grasp the vial. sequence.
• The vial was dropped during transfer 2 Make sure that the sample vials
to or from the turret. meet recommended specification.
• The sensor in the gripper is 3 If you are using adhesive labels,
defective. verify that the labels are properly
• The vial does not meet installed. See “Label a sample
specifications. vial” on page 168.
4 If the error recurs frequently, obtain
Agilent service.

Tray not present • There is a board failure in the tray or 1 Make sure that the tray cable
GC. connection is secure.
• The tray cable is bad or not 2 Replace the tray cable.
connected between the GC and tray. 3 If the error remains, obtain Agilent
• There is a cable failure in the GC. service.
Tray offline • There is a board failure in the tray or 1 Make sure that the tray to GC cable
GC. connection is secure.
• The tray cable is bad or not 2 Replace the tray cable.
connected. 3 If the error remains, obtain Agilent
• There is a cable failure in the GC. service.
Invalid sequence • The sequence is set up for the 1 Make sure that the connection to
wrong injection device. the GC is secure.
• Hardware required by the sequence 2 Verify the sequence parameters
is not installed and configured. against the GC configuration.
• The GC configuration was changed 3 If the error remains, obtain Agilent
during sequence execution. service.
• The injector cable is bad or not
connected properly.
No injector • The cabling connection to the GC 1 Make sure that the connection to
became loose during a run. the GC is secure.
• An injector board or GC board failed 2 If the error remains, obtain Agilent
during a run. service.
Prerun >10 min • The GC is Not Ready. • Check for Not Ready and other GC
messages to determine the cause.
Sampler Offline  • You are attempting to upload or • Make sure that the connection to
(6890A/Plus GCs Only) download an ALS workfile to an ALS the GC is secure.
system that is not powered on or
connected.


13
Troubleshooting
The information in this chapter will assist you in keeping the sampler
running smoothly.
If the chromatogram is not satisfactory, clearly something is wrong. Use
this chapter to determine the probable cause and, in many cases, the cure
for the problem.
This chapter deals only with sampler- related problems. However, many of
the symptoms described here could also come from other sources,
particularly the stability of the GC temperature and its gas supplies.
If you cannot correct the problem, obtain Agilent service.

13 Troubleshooting
Symptom: Variability
Figure 79 Retention times or areas are not reproducible
Table 21 Variability problems
Possible cause Action
Inlet septum is leaking. If the septum is leaking, replace it. If the septum you replaced
experienced less than 200 injections, check for the following
possible problems to prevent premature septum failure:
• The septum retainer nut is too tight.
• The syringe needle is not straight.
• The syringe is not installed correctly.
Syringe is worn or dirty. If the syringe looks dirty or the plunger is sticking, clean the
syringe with an appropriate solvent or follow the syringe
manufacturer’s cleaning instructions.
Sample volume is too low or too Check sample level. If the sample vials are not filled correctly,
high. evaporation or contamination may affect the analysis. The
sample level hold will be approximately half the volume of the
vial. See “Fill a sample vial” on page 169.

Troubleshooting 13
Table 21 Variability problems (continued)
Vial caps are loose. Check vial caps. If you can turn the vial crimp cap by hand,
they are too loose. Loose caps may cause volatile samples to
change concentration over time. See “Cap a sample vial” on
page 170.
Screw caps, if not sufficiently tight, can come loose in the
mixer and even come off.
Sample is not stable. Check the sample stability. Some samples change with heat
or ultraviolet light. There are several ways to reduce changes
to unstable samples:
• Use the vial racks to cool the sample.
• Use amber sample vials.
• Store the samples in a protected environment.
Sample size varies. Install a new syringe. If the sample size varies, the syringe is
probably not precise or the plunger is worn. Variation may be
due to syringes with removable needles because of dead
volume or needle-to-needle variation.
Air bubbles are in the needle. If air bubbles are in the needle, user variable speed and a
sample draw speed slow enough to avoid bubble formation.
See “Setting the Injector Parameters” on page 142.
If this does not help and the sample is viscous, try the
following:
• Increase the viscosity delay time.
• Use the vial racks to warm the sample.
• Dilute the sample in an appropriate low-viscosity
solvent.

13 Troubleshooting
Symptom: Contamination or Ghost Peaks
Table 22 Contamination or ghost peak problems
Vial cap septum is dissolving in Check for the following:

solvent. • Be sure the vial septum is flat. If the vial septum is not
Ghost peaks sometimes appear flat, the needle tends to core the septum and drop
when small pieces of septum pieces into the sample. See “Cap a sample vial” on
material dissolve in the sample. page 170.
Make several blank runs to • Check the needle. If the syringe needle has burrs, it
determine the presence or could cut pieces of the septum and push them into the
absence of the ghost peaks. sample.
• Check the vial septum. If the vial septum is not resistant
enough to the solvent you are using, try a more
resistant type.
Sample vials are contaminated. Ghost peaks are sometimes caused by contaminated sample
vials. Try new or clean vials to see if ghost peaks disappear.
Store new vials in a contaminant-free location.
Inlet septum is giving off volatiles. Make several blank runs with a small piece of aluminum foil
backing the inlet septum. If the contamination peaks
disappear, they were probably due to the septum. Try
replacing the septum you usually use with another type.
Column is contaminated. Do the following:

High molecular weight samples • Replace or clean and deactivate the inlet liner.
that contain residues may cause • Examine the first few inches of a capillary column for
the syringe, the inlet liner, or the foreign material by holding a light behind it. If possible,
first few inches of column to remove the contaminated section.
become contaminated.
Sample is not stable. Some samples change with heat or ultraviolet light. Check the
sample stability.
There are several ways to reduce the change:
• Use the tray quadrant to cool the sample.

Troubleshooting 13
Symptom: Smaller or Larger Peaks Than Expected
Automated injection
Manual injection
Figure 80 Smaller or larger peaks than expected
Table 23 Peak size problems
You are comparing a Check your injection mode. In the normal injection mode, the
chromatogram without needle sampler uses fast injection to deliver a representative amount
fractionation against one with of the sample. Fast injection minimize needle fractionation.
needle fractionation. Chromatograms from manual injection or slower auto
injection devices show higher levels of low molecular weight
materials versus higher molecular weight materials because
the volatiles boil out of the needle faster than the higher
weight materials.

13 Troubleshooting
Table 23 Peak size problems (continued)
You are using a packed inlet and a Check your inlet. Capillary columns used with packed inlets
530-µm column. have some inherent sample discrimination characteristics.
There is a leak in the GC system. Replace the septum and check the fitting for leaks. If the
leaking septum has experienced less than 200 injections.
To prevent future premature failures, be sure that:
• The septum retainer nut is not too tight.
• The syringe needle is straight.
• The syringe is installed correctly.
Sample is not stable. Some samples change with heat or ultraviolet light. Check the
sample stability. There are several ways to reduce the change:
• Use the vial racks to cool the sample.
Vial caps are loose. Check the vial caps. Loose vial caps can cause selective loss
of lighter materials from a sample. The cap should not rotate
easily if installed properly. See “Cap a sample vial” on
page 170.

Troubleshooting 13
Symptom: Sample Carryover
Figure 81 Blank run showing carryover peaks
Table 24 Carryover problems
Number or type of washes is Check the run parameters for the number of sample and
insufficient. solvent washes. The number of washes needed depends on
your application. See “Sample Carryover” on page 122.
You ran out of solvent. Check the solvent bottles. If the solvent level is below 2.5 mL,
the syringe cannot reach the solvent. Replace the remaining
solvent with 4 to 4.5 mL of fresh solvent. See “Preparing
Solvent and Waste Bottles” on page 172.
Check the waste bottles. If the waste level is near the neck of
the bottle, replace it with an empty bottle.
Syringe is worn or dirty. If the syringe look dirty or the plunger is sticking, clean the
syringe with an appropriate solvent or follow the syringe
manufacturer’s cleaning instructions. If the syringe seems
worn, replace it.
Samples (vial-to-vial) are of In this situation, the sample and solvent washes may not
immiscible types. rinse the syringe properly. Increase the number of wash
cycles or use a solvent that rinses a variety of sample types.

13 Troubleshooting
Symptom: No Signal/No Peaks
Table 25 Signal/Peak problems
Syringe plunger is malfunctioning. Verify that the syringe plunger is secured by the plunger
screw. If the plunger screw is loose, tighten it. See“Installing
a Syringe” on page 158.
Check the syringe needle for plugging. If the syringe is
plugged, replace or clean the syringe.
Sample level is too low in vial. If there is no or very little sample in the vial, the needle may
not be able to reach it. See “Fill a sample vial” on page 169.
Alternately, you may edit your method to adjust the needle
sampling depth. See Sampling offset in “Setting the Injector
Parameters” on page 142.
Sample is viscous. If the sample is viscous, try the following:

• Increase the viscosity delay time.
• Use the vial racks to warm the sample.
• Dilute the sample in an appropriate low-viscosity
solvent.

Troubleshooting 13
Correcting Syringe Problems
When troubleshooting the injector, keep your hands away from the syringe needle.
WA R N I N G
The needle is sharp and may contain hazardous chemicals.
Several things can cause syringe needles to bend. When you find one,
check for the following conditions before installing a replacement:
 Was the syringe installed properly in the syringe carriage?
 Are you using the correct syringe type? Is the combined length of the
syringe barrel and needle 126.5 mm? For more information, see
“Selecting a Syringe” on page 154.
 Is the needle support foot clean? Remove any residue or septum
deposits. For more information, see “Periodic Maintenance” on
page 200.
 If performing a cool on- column injection, is the correct insert for your
syringe installed in the cool on- column inlet? For more information, see
“Adapting for Cool On- Column Injection” on page 212.
 Is the GC septum nut too tight? For more information, see your GC
operating documentation.
 Is the septum of the crimp cap centered over the sample vial? For more
information, see “Cap a sample vial” on page 170.
 Are the inside diameters of the sample vial, microvial insert, and vial
cap septum at least 5 mm? For more information, see “Preparing a
Sample Vial” on page 166.

13 Troubleshooting
Correcting Sample Vial Delivery Problems

When you find a mishandled sample vial, check:
 Are the vial caps installed correctly?
 Are there folds or wrinkles in the crimp cap, especially near the neck
of the sample vial? For more information, see “Preparing a Sample
Vial” on page 166.
 If you use labels on the sample vials, are they the correct size? For
more information, see “Label a sample vial” on page 168.
 If you use labels on the sample vials, are they interfering with the
gripper? For more information, see “Label a sample vial” on page 168.
 Are there any obstacles to the sample tray arm or injector turret
motions? Remove any obstacles.
 Are the vial racks and turret in good condition? Clean any residue from
the sample positions.
 Does the bottom of a sample vial touch the top of the turret? To
calibrate the ALS system, see “Calibrating the ALS System” on
page 229.
 Does the side of a sample vial touch the side of the turret hole as the
vial is raised or lowered? To calibrate the ALS system, see “Calibrating
the ALS System” on page 229.

14
Replacement Parts
G4513A Injector 254
The following pages list the replacement parts for the 7693A ALS system.
Also refer to the Agilent web site at www.agilent.com/chem for the most
up- to- date replacement part and firmware listings.

G4513A Injector
Table 26 and Figure 82 list and show the replacement parts for the
G4513A Injector module.
Table 26 G4513A Injector replacement parts
Item Description Part no. Qty/Assy
1 Transfer turret G4513-67730 1
2 Standalone turret G4513-40532 1
3 Needle support insert - Standard G4513-40525 1
4 Needle support insert - COC G4513-40529 1
5 Dual parking post 05890-61525 1
6 Injector mounting post G4513-20561 1
7 Injector module (new/exchange) G4513A 1
8 Communication cable G4514-60610 1

1 2 3 4 5 6
7 8
Figure 82 G4513A Injector replacement parts

G4514A Sample Tray

G4514A Sample Tray.
Table 27 G4514A Sample Tray replacement parts
1 Vial rack G4514-63010 3
2 L Key Torx T-20 8710-2430 1
3 L Key Torx T-30 G4514-80524 1
4 Tray bracket insulating washer G4514-20529 1
5 M4 × 33.3 screw 0515-0437 1
6 M6 × 25 screw 0515-0192 3
7 Gripper finger caps G4514-60710 16
8 M4 × 0.7 screw 1390-1024 4
9 Calibration vial G4514-40588 1
10 Mounting bracket G4514- 63000 1
11 Bar code reader/mixer/heater G4515A 1
12 ALS main cable assembly G4514-60610 1
13 Vial rack label kit G4525-60701 3
NS Heating and cooling plate G4522A 1
NS Vial rack set of 3, with 12 label G4525A 1

tags (4 colors)

3
2
4 5
1 7
8 9
13
10
12
11
Figure 83 G4514A Sample Tray replacement parts

G4517A ALS Controller (6890A GC Only)

G4517A ALS Controller (for 6890A GCs only).
Replacement of internal fuses and the battery can expose the servicing person to
WA R N I N G
hazardous voltages and also exposes the controller to damage. Replacement is not
covered in this manual. Refer servicing to qualified, Agilent-trained personnel.
Table 28 G4517A ALS Controller replacement parts
Item Description Part No. Qty/Assy
1 G4517A Controller (new) G4516-64000
2 Fuse, 2 A 250 VAC
NS Fuse, power supply PCA
NS Fuse, ALS controller PCA
NS Battery, 3 V .5 A, Lithium ion

1 220-240 V
USE ONLY WITH 250V
FUSES/EMPLOYER
UNIQUEMENT AVEC
110-120 V
Back panel
V
250 PE T A 2
TY A 2
2
Figure 84 Replacement parts for the G4517A ALS Controller

G4516A ALS Interface Board (6890 Plus GC Only)
Table 29 G4516A ALS Interface Board replacement parts
NS ALS Interface Board controller G4517-64000 1


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Agilent 7693A 

Installation, Operation and

2 Installation, Operation, and Maintenance

Part 1: Safety and Regulatory Information

1 Safety and Regulatory Information

Installation, Operation, and Maintenance 3

4 Installation, Operation, and Maintenance

Installation, Operation, and Maintenance 5

6 Installation, Operation, and Maintenance

8 Syringes and Needles

9 Vials and Bottles

Installation, Operation, and Maintenance 7

Part 4: Maintenance and Troubleshooting

8 Installation, Operation, and Maintenance

12 Faults and Errors

Installation, Operation, and Maintenance 9

10 Installation, Operation, and Maintenance

This chapter provides important safety and regulatory information about

Important Safety Warnings

Many internal parts of the instrument carry dangerous voltages

Electrostatic discharge is a threat to instrument electronics

14 Installation, Operation, and Maintenance

Safety and Regulatory Certifications

The instrument is designed and manufactured under a quality system

Installation, Operation, and Maintenance 15

Refer servicing to qualified service personnel. Substituting parts or

See accompanying instructions for more

Indicates a hot surface.

Indicates hazardous voltages.

Indicates earth (ground) terminal.

Indicates explosion hazard.

Indicates electrostatic discharge hazard.

Technical and environmental specifications

16 Installation, Operation, and Maintenance

• Pollution degree 2, Installation Cat II

Sound Emission Certification for Federal Republic of Germany

Installation, Operation, and Maintenance 17

Fuses and battery

Table 1 G4517A ALS Controller fuses

Fuse designation Location Fuse rating and type

2A G4517A Power line module 2A 250V, type T (220–240 V power supply)

2A G4517A Power line module 2A 250V, type T (100–120 V power supply)

The G4517A ALS Controller also contains a non- replaceable 3 V lithium

Recycling the Product

18 Installation, Operation, and Maintenance

Table 2 Minimum GC firmware revisions for 7693A ALS system use

Instrument Minimum firmware version required

6890A GC A.03.08 (chip set)

6890 Plus GC A.03.08 (chip set)

6850 GC with serial number < US00003200 A.03.07

6850 GC with serial number > US10243001 A.06.02

7820 MSD A.01.01 (GC)

5975T LTM-GC/MSD A.03.02.005 (GC) / 5.02.07 (MSD)

22 Installation, Operation, and Maintenance

The G4513A Injector

The G4514A Sample Tray

The G4515A Bar Code Reader/Mixer/Heater

The G4520A Sample Tray with Installed Bar Code Reader/Mixer/Heater

The G4522A Heating and Cooling Plate

Installation, Operation, and Maintenance 23

The G4526A Upgrade Kit for 6890 Series GCs

24 Installation, Operation, and Maintenance

1 Set the GC inlets, detectors, and oven to room temperature.